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Investigation of an Electrodynamic Magnetic Levitation Device

Conference Paper · July 2020

DOI: 10.1109/EIT48999.2020.9208281

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 Investigation of an Electrodynamic
Magnetic Levitation Device
Attila Lendek, StudentMember, IEEE Constantin M. Apostoaia, Member, IEEE
Dept. of Electrical and Computer Engineering Dept. of Electrical and Computer Engineering
Purdue University Northwest, Hammond, IN Purdue University Northwest, Hammond, IN
[email protected] [email protected]

Abstract — This study is done in the area of magnetic This paper research work is focusing on the study of
levitation, with future application for transportation electrodynamic magnetic levitation, and the development of
electrification. The type of the device designed and implemented an experimental prototype, for test.
in this work, is known as an electrodynamic magnetic levitation
system (EDS). First, a simulation model of the EDS is developed, The paper is organized in six sections. In the Introduction
which employs Halbach arrays, that are a special arrangement of section, the motivation of the EDS device development, and
permanent magnets, on rotational discs (rotors), placed above a investigation is presented. The work in progress is discussed
conductive plate. The finite element analysis model of EDS is elsewhere. In the second section, a brief background is
designed, and simulated using ANSYS Maxwell™ software. presented, referring to the theoretical concepts involved in
Second, an electrodynamic levitation device was designed, built magnetic levitation. In the third section, a detailed analytical
and experimentally investigated. Proof of concept was carried out mathematical model of the EDS system is developed. In the
through modeling, simulation and experiments, on a scaled-down fourth section, the modeling, and simulation of the EDS
built physical model, using speed controlled permanent magnet device is examined in two steps: first, the model based on
AC motors, to drive the Halbach rotors. FEA design is presented, and in a second step, the overall EDS
models simulation results are discussed. The fifth section
Keywords — electrodynamic magnetic levitation system, presents the development, and realization of the experimental
Halbach array, magnetic lifting force, simulation, finite element
device, at a reduced scale, for the system’s experimental vali-
analysis, experimental model.
dation. The concluding remarks are outlined in the last section.
I. INTRODUCTION
II. ELECTRODYNAMIC LEVITATION BACKGROUND
The advanced technology of magnetic levitation has been
already employed in various applications such as: At the core of the electrodynamic levitation device is a set
-in industrial equipment in fans, pumps, compressors, of permanent magnets, with a specific arrangement in a so
motors, generators, using magnetic bearings without physical called Halbach array. As proposed by the physician Klaus
contact Halbach in 1985 [11], a Halbach array of magnets allows
-in transportation systems, for high speed magnetically concentration of the magnetic field in a desired direction. The
levitated (Maglev) trains, personal rapid transit array has a spatially rotating pattern of magnetization, which
-in space launch vehicle (NASA’s Space Flight Center), to almost cancels the field on one side but, boosts it on the other.
break free from Earth’s gravity The main advantages of Halbach arrays are, that they can
-in clean energy for frictionless wind turbines produce about 1.4 times stronger magnetic fields on one side,
-in civil engineering for elevators whilst creating a very small (stray) field on the opposite side.
-in nuclear energy for centrifuges of nuclear reactors, and In the beginning of this study, a linear Halbach array was
even for implantable heart pumps. investigated.
Common to all these applications is the lack of contact (no In Fig.1, the simulation of the magnetic field lines,
wear and friction), and thus, increased efficiency with reduced generated by a linear arrangement of five 1-inch neodymium
maintenance costs, overall increasing the life of the systems. type cube magnets, is shown. The physical realization of this
Maglev is certainly considered as a solution for the world linear Halbach array is described later in section V.
needs of future clean energy applications.
The rotational, or translational motion of a permanent
magnet above a copper or aluminum conductive plate, creates
an electrodynamic levitation, and drag force. At low speeds,
the drag force dominates [1]. Because of this dominating drag
force, it is not suitable for low speed operations [2].
Significant reduction in the drag forces can be achieved by the
null current approach [3].
The implementation of EDS in transportation, is an
attractive idea because of the Halbach Arrays unique property
of producing a strong periodic magnetic field, concentrated on
one side[4] [5] [6]. Fig.1 Magnetic field lines simulation of a Halbach array using ANSYS
There is a critical speed that must be reached, for the Maxwell software.
implementation of the magnetic levitation. Until this speed is
achieved, other means must be implemented, then magnetic Note that a weak magnetic field is present on the top side of
levitation can take over [7] [8] [9]. the device, whilst on the bottom side, a strong magnetic field
Magnetic levitation systems can be divided into two groups: is created. This array arrangement uses four blocks per spatial
the attractive systems, which are called electromagnetic period, with the magnetization axis rotating by 90 degrees, in
suspension, and the repulsive systems, which are called each subsequent block. The arrows in Fig.1 indicate the
electrodynamic suspension [10]. magnetization vector’s direction.
 In the next step of this study, the magnets of Halbach array
are assembled on a rotational disc (rotor), which is placed on In order to solve for the eddy currents, substitute Eq. (3) into
top of a conductive plate. Fig.2 shows the rotor containing a Eq. (2) to obtain:
radial Halbach array magnet arrangement, which creates six
poles, with four magnets per spatial period (South poles are ωΦ ω (4)
marked with a cross, while the North poles are marked with
dots).
In (1), (3) and (4), the excitation frequency ω is related to the
The motional magnetic field from the Halbach array mechanical rotational speed of the Halbach rotor ω , by the
magnets, induces an electromotive force (emf) in the shorted
number pairs of poles:
circuit of a conductive plate, and thus eddy currents are
induced in the plate.
ω ω (5)

The steady state sinusoidal response , is conveniently

found using the electric circuit theory, as shown next. In the
input-output (I/O) model of EDS given in Eq. (4), the
following Laplace transforms are identified:

≡ ωΦ
(6)
≡
Fig.2 Halbach magnet array on a rotor.
Correspondingly, the I/O model of the EDS based on the
The eddy currents create an induced (secondary) magnetic transfer function concept is given by:
field, opposing to the change of magnetic fields of the
permanent magnets. In this way, a repelling, levitation (lifting)
(7)
magnetic force is created. And if the rotor of the permanent
magnets remains in motion, above a minimum speed of
rotation, the rotor will be stably levitated. Then, the steady-state solution for eddy currents is given as in
[12]:

III. EDSMATHEMATICAL MODEL ωΦ | ω | cos ω θ ω , (8)

The schematic representation of the EDS concept is shown
in Fig.3, with a Halbach array rotating above, and close to a
conductive plate. | ω |
where, (9)
θ ω atan

Finally, substitute (9) in (8) to obtain:

cos ω sin ω (10)

Fig.3 Halbach array rotor above a thin conductive plate.

At the limit, with ω ω ≫ , the sinusoidal steady-state
The Halbach array is canceling the magnetic field above it, solution is obtained from (10) as:
while producing a nearly purely sinusoidal varying periodic
magnetic field below the array: cos ω 90° (11)
ω , (1)
Note that in (11) the current is shifted 90° , in phase with
where, is the peak value of the flux. respect to the inducing voltage in (3), so that is in
phase with the magnetic flux given in (1), maximizing the lift
The analysis of the magnetic levitation is simplified here force.
through lumped parameter electric circuit theory, and basic
laws of electromagnetism. Thus, the voltage circuit equation Using the theory of plane-electromagnetic wave
relating the voltage (emf) induced, and eddy currents in the propagation, the wave number of the magnetic field of the
conducting base plate is written as: Halbach array is defined as in [13]:

, (2) , (12)
where, λ(m) is the wavelength of the array, ω is the
where, L, R are the inductance and resistance parameters excitation frequency of magnetic field given in (5), and is
of the conductive circuit. the magnets apparent linear velocity ( ω , in the z-
The magnitude of , in accord to Faraday’s law is: direction in m⁄s .
Since we calculate the lifting force on a magnet array, we
ωΦ ω (3) replace ω by in (10) and (11), with k given in (12).
 The coordinate system used here, has its origin situated on 1.0). With the definition of K in (20), the transition
the upper surface of the conductive plate, with y-axis pointing velocity , is defined as the velocity where 1.0.
towards the magnet array, x-axis pointing across the plate, and The conductive plate thickness d, it is assumed to
the z-axis in the direction of apparent (linear) motion along the considerably exceed the standard skin-depth , which is given
plate. The separation distance between the plate and the lower by:
surface of the Halbach array is denoted by the gap, g (Fig.3).
The calculation of the generated lift and drag forces, δ (21)
requires the expressions of the longitudinal-z and vertical-y
components of the magnetic field of Halbach array. These are where, ω 2 is the operating excitation frequency,
given with a close approximation as in [14] [15]: μ μ 4π 10 (H/m) is the magnetic permeability of
the conductive plate, and σ its electrical conductivity.
sin (13, a)
For a copper conductive plate (σ 5.88 10 S⁄m)),
cos (13, b)
and a Halbach array with six poles, at a rotational speed of
where, is the peak flux density at the surface of the 4875 (rpm), the skin depth is δ 4.2(mm); while for an
Halbach array (at y = g). aluminum plate (σ 3.5 10 S⁄m)), the skin depth is
The expression of the induced flux Φ, is derived by δ 5.4(mm).
integrating (13a) over y, between 0 and (Fig. 3), The induced eddy currents flow only in this relatively thin-
where d is the thickness of the conductive plate [14]: skin layer, not occupying the whole thickness d, of the plate.
Therefore, the Joule (heat) losses are expected to increase.
Φ sin 1 (14)
In the limit case δ ≪ 1, in practical situations when the
where, (m) is the width of the magnets in the x- skin depth is small compared to the wavelength, the
direction, transverse to the direction of motion above the plate. expression for the lift-to-drag ratio (when using a copper
Inserting peak value of the flux from (14) into (10), the plate) reduces to:
expression for the current in the x-direction , is found as:
2.425 (22)
sin cos (15)

This current then interacts with the rotor magnetic field, to IV. SIMULATION AND PERFORMANCE INVESTIGATION OF
produce the levitating force in the vertical y-direction, and the ELECTRODYNAMIC LEVITATION SYSTEM
drag force in the horizontal z-direction: The goal is to determine the best design solution, to achieve
a lifting force capable to levitate a physical prototype. The
, (16a, b) main objectives addressed, are to enable the electrodynamic
Averaging the expressions of the forces’ magnitudes over the levitation system to (a) achieve the expected lifting force by
wavelength, then, the average maintaining at minimum the number of magnets, their size and
weight, and (b) stably operate in dynamic and stationary
forces are found as follows: conditions.
The approach applied here to achieve these objectives, is
Lift force: using computational electromagnetics model-based design
technique. Due to the specific 3D nature of this application,
(17) where phenomena such as the depth of penetration of varying
electromagnetic fields, and eddy currents effect are present,
Drag force: the classic analytical calculations are difficult to use for
simulation, and visualization of the mentioned phenomena.
(18) The solution chosen in this paper is to employ the finite ele-
ment analysis (FEA) based software, ANSYS Maxwell™
[17]. In this way, the value of the lift force produced by the
A good measure of the efficiency of the magnetic levitation Halbach array, mounted on a spinning rotor, at high speed, is
system is given by the lift-to-drag ratio, dividing (17) by (18): accurately calculated, and extracted for further analysis.

(19) The Maxwell 3D design of two preliminary variants of

Halbach magnet rotor models used in this paper, are shown for
Note that / ratio increases with the tangential velocity, exemplification, in Fig. 4.
, while the drag force is varying inversely with
velocity.
Using (19), a parameter K is defined by the expression [14]:

(20)
The parameter K in (20) measures the levitation efficiency
of the system. Note that the units of measure for K is (s/m), (a) (b)
reciprocal of velocity units, or (N/watts). Fig.4 Preliminary Halbach rotor design:(a) one array of NdFe61 magnets;
Another useful design quantity is the “transition velocity”, (b) NdFe55 magnets in three-concentric arrays.
defined as the velocity at which, the lifting force has reached
on half of its asymptotic value, and at the same time, is the In Fig.4 (a), the rotor contains a circular shape Halbach
velocity at which the lift and drag forces are equal ( / magnet array, using NdFe61 magnets, with a magnetic
coercivity of -890 (kA/m). The array geometry data is: outer generated by the final rotor design, are shown in Fig. 8 and
diameter of 120 (mm), inner diameter 70 (mm), magnet axial Fig. 9, respectively.
thickness 8 (mm). The magnetization arrangement of the The practical construction of the experimental device, to test
Halbach array (Fig.2), creates strong six poles field directed and validate the simulation of the final rotor model, and to
axially towards the copper plate, placed underneath, at 8 mm demonstrate the proof of concept, is presented in the next
gap separation. The simulation is performed in Maxwell 3D, section V.
using a transient solution with a rotor velocity of 4,400 (rpm).
The returned results are the calculated flux density 0.8 (T) in
the gap, and the lifting force magnitude of 288 (N). The
simulation of the induced eddy currents in a copper plate,
generated by the rotor design shown in Fig. 4(a), is displayed
in Fig. 5.

Fig.7 Final design of the Halbach rotor with two concentric arrays of NdFe52
magnets.

Fig.5 Eddy currents generated by a 12-magnet rotor.

In Fig. 4(b), the rotor contains three concentric Halbach

arrays, using NdFe55 magnets, with the following data: most
outer diameter 120 (mm), most inner diameter 37 (mm),
magnet axial thickness 13 (mm). The Maxwell 3D transient
solution, returned the calculated flux density of 1.1 (T) in the
gap, and the lifting force magnitude of 1296 (N). The
simulation of the induced eddy currents in the conductive
plate, generated by this rotor design (Fig. 4(b)), is shown in
Fig. 6.
The final design variant has been decided based on the Fig.8 Magnetic flux density of the Halbach rotor final design (rotor’s bottom
analysis of simulation results, obtained with the two side facing the gap shown).
preliminary models of the Halbach magnet rotors (Fig. 4), and
verifying the objectives mentioned at the beginning of this
section.

Fig.9 Eddy currents induced using the Halbach rotor final design.
Fig.6 Eddy currents induced using three arrays of 12 magnets each.

The final model design shown in Fig.7, consists of a rotor V. EDS EXPERIMENTAL DEVICE
with two concentric Halbach magnet arrays, each one using 12 The goal of building an EDS device was the proof of
magnets with four magnets per spatial period, which create six concept, and the ability to physically make measurements that
magnetic poles. The following is the final design data (see can be related to the software simulations.
Fig.7): inner diameter of the inner magnet array 52 (mm),
The first device built in this work is a linear Halbach array,
outer diameter of the outer array 105.2 (mm), NdFe52 cube
magnets with 0.5-inch (12.7 (mm)) long edges. The array’s which is comprised of five 1-inch neodymium type cube
thickness of 12.7 (mm), is equal to one quarter of the spatial magnets, shown in Fig.10. The magnetization vectors of the
period, and thus this array is easily fabricated (see section V) cube magnets point from the South pole toward the North
since the blocks are identical, and are simply rotated as the pole. The magnets are positioned so that the magnetization
array is assembled. vector is rotating in the same plane, 90 degrees from one
magnet to the next. Due to this specific arrangement, the
The simulation of the final rotor design model (Fig.7), is adjacent magnets do exert forces on each other, and thus a
performed in Maxwell 3D, at a rotor velocity of 4,400 (rpm), housing is needed around the array, which will keep them
and using a transient solution. The solution returned is for the aligned and compact in the above-mentioned setup, shown in
calculated flux density of 1.0 (T) in the gap, and the lifting Fig. 10(a). The housing was designed in SolidWorks, and
force magnitude of 687 (N). The simulation results of the flux printed out of ABS (Acrylonitrile butadiene styrene), on a 3D
density, and the induced eddy currents in the conductive plate printer. The strength of the magnetic field of this array can be
visualized using a magnetic viewing film, as displayed in magnets, in radial arrangement, with each of the magnets
Fig.10 (b). being rotated 90 degrees at each step, creating six poles
around the array. Several factors played a role in considering
the array fit for this project such as: the robustness, weight,
and size. The rotor in the middle (Fig.11) offered less poles
and light weight, by compromising the robustness of the array
at high speeds.
The rotor on the top right (Fig.11), offered strong fields
because of the number of magnets in the array. Comparing the
top right (white) variant, to the design variant on the top left
(orange), by measuring the weight of the whole array, there is
a compromise to be made in between the strength of the
(a) magnetic field, to the weight of the array. As more and more
arrays of magnets are placed in radial direction, the number of
magnets cannot be increased in the rows further away from the
center of the array. This results in increased space, in between
the magnets, in azimuthal direction, that must be filled with
base structure material. This process will add more weight to
the array, while places the magnets further apart, weakening
the magnetic fields.
(b) The experimental tests on these physical prototypes were
conducted in a safe environment, with eye protection. Using
Fig.10 (a) Built linear Halbach array (b) Field visualization through magnetic
viewing film: on the left the weak side, on the right the augmented side
the Bosch Hammerdrill 1199VSR that provided 3000 rpm, all
showing two large magnetic poles. rotors were initially tested for lifting force evaluation, above a
copper and an aluminum plate, Fig. 12.
Next stage in the design, is the implementation of a Halbach
array that can be used in generating a dynamic magnetic field.
This is a radial Halbach array, in which, the magnets are
placed in an equal radial distance from the center of the base
disk. The magnets are rotated in the same plane, so that the
augmented side of the array is perpendicular to one of the
faces of the disk, leaving the other face to the weak side of the
magnetic field.
Several designs were drawn in SolidWorks, and printed out
of ABS, with the help of a 3D printer. The design variants
worth mentioning are shown in Fig.11, where the main
differences in the design can be seen.

Fig.12 Initial testing of the radial Halbach arrays.

Considering the tests findings, the implemented EDS variant

confirming the simulated final design (Fig. 7, 8, 9) was the
one on top left in Fig.11 (orange), with small modifications,
where the radii of the arrays and rotor disk were reduced to a
Fig.11 Radial Halbach arrays (top), viewed through the magnetic viewing film safe minimum, so the structure remained sound, and the arrays
(bottom). Each array has its corresponding visible field underneath it. are as tight as possible. The outcome of the final implemented
The array on the top left (orange color in Fig.11), has two design can be seen in Fig.13.
sets of ½ inch cube magnets in radial arrangement, with each The design accounted for the coupling of the rotor to the
of the magnets being rotated 90 degrees at each step. This way axis of the driving motor, with the countersink in the middle
the magnets create six poles going around the array. The array of the rotor. The rotor disk in Fig.13 was then loaded with ½
in the middle (black in Fig.11), was created with rectangular inch magnets glued into place.
shape neodymium type magnets with their magnetization
vector being perpendicular to the axial length of magnets. This
disk array housing allows the magnets to be placed on the
edge and on the side, this way allowing the construction of an
array where the magnetization vector is rotated 45 degrees at
each step. This leads to a reduced number of augmented
magnetic poles, which are four in this case. The array on the
top right (white color in Fig.11), has three sets of ½ inch cube
 Fig.13 Radial Halbach arrays housing final design, 3D printed from ABS
material.
The glue was applied to 5 sides out of 6 of each magnet, (c) (d)
accounting for a minimum 80% of the magnets surface in Fig.15(c) CNC machine drilling), (d) manual countersink drilling.
contact and glued to the surface of the housing.
The initial assembly of the four motors, controllers and
In the next step of this work, to drive the assembled radial Halbach rotors on the frame is shown in Fig.16.
arrays at high rotational speeds, the Axi 5330/24 outer runner
brushless direct current (BLDC) motor has been selected. The
selection was made on the several criteria such as: required
power sources, provided torque, and maximum speed.
The BLDC motors are open loop voltage controlled by the
Jeti Advance Opto 77 ampere controllers, with 1V/197 rpm.
An Arduino Uno was used to create 50Hz pulse with
modulation (PWM) signals, to simply act as the throttle for the
controller.
With the rotor driven by the motor, the testing of the
dynamic magnetic fields could be performed. The static and
dynamic magnetic fields where measured using a F.W. Bell,
Model 5070, Gauss/Tesla Meter (Fig. 14). The dynamic flux
density was measured at 4010 rpm, and yielded B = 0.29 (T).
(a) (b)
The static flux was measured to be strongest across two Fig.16 (a) Rotors with loaded Halbach arrays facing up, (b) the frame with
opposing poles, B = 0.602 (T). motors, controllers and Halbach arrays facing down.

(a) (b)
Fig.14 Testing the strength of the magnetic fields, (a) dynamic and (b) static.

The chassis of the EDS device was machined from a 1 , ¼ (a) (b)
inch thick aluminum plate with the goal to accommodate four Fig.17(a) Safety barrier components with the interlocking parts designed in
BLDC motors symmetrically placed, Fig. 15. SolidWorks, (b) final assembly of the barrier around the device
Because of the dynamic nature of the device operating at The weight of the assembly is 6618 (g), with a 182 (g)
high rate of speed, a safety barrier was designed around it as carrying tray that was designed to be attached on the top of the
shown in Fig.17 and Fig.18. It also plays the role of footing device. The overall weight is 6800 (g), or 15 (lb.).
for the device, this way the device can rest on the safety
barrier whenever not levitating. The safety barrier was design Tests were conducted above a copper, and an aluminum
in SolidWorks, printed out in ABS with a 3D printer. plate, at different speeds. The air-gaps were measured and
recorded at different speeds (Fig. 20), and also at different
weights

(a) (b)
Fig.15 (a) Cutting design in SolidWorks), (b) plasma cut plate.
 EDS device has then been built in this work and successfully
validated the proof of concept.
The variation of the most important parameters in
electrodynamic levitation systems, which are the magnets
coercivity, their spatial arrangement, the magnet size and their
number, the excitation frequency determined by the
mechanical velocity and the number of poles, all have been
simulated using ANSYS Maxwell software. The influence of
parameters variation on the generated magnetic flux density,
induced eddy currents, and on the magnitude of the lifting
levitation force, were reported.
Four outer rotor AC permanent magnet motors have been
interfaced with controllers and then used to build a physical
device of the designed EDS prototype. The implemented
electrodynamic system stable operation has proved the
Fig.18 Final assembly of the EDS device concept of magnetic levitation by experiments and test results
were reported.
In Fig. 19 the magnetic fields can be observed with all four of
mounted Halbach arrays. This viewing represents the strong
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