Deformation Effects in Magnetic Guides: Challenges and Solutions with Sensors

Magnetic guides facilitate frictionless movement in machine tools, allowing for high position accuracy and high feed rate dynamics. However, achieving a stable state while subjected to machining forces requires a high magnetic force, which will cause deformation of the surrounding construction. This deformation leads to the contraction of the air gap between the slide and guideways. The air gap has a quadratic effect on the magnetic force, which poses a challenge to the control system. In addition, the effect of elastic deformation on magnetic guides is difficult to detect in real time due to the interference of magnetic fields in sensors and installation space constraints. In order to quantitatively analyze the effects of magnetic guide deformations, particularly of electrical steels, a combined approach of numerical analysis and experimental evaluation was conducted. As a result, the deformation of electrical steels, which is typically overlooked in conventional applications, is identified and analyzed. Force stabilization is achieved through adaptive set point correction and current adjustment, ensuring reliable and accurate operation of the magnetic guide system.