For decades, sensorless position estimation methods gained lots of interest from the research community, especially in the field of electric drives and active magnetic bearings (AMBs). In particular, the direct flux control (DFC) technique promises unique advantages over other sensorless techniques, such as a higher bandwidth, but on the other hand, it requires the coils to be connected in a star topology. Until now, star-point connections are rarely found on active magnetic bearings. In consequence, there is no known publication about the application of the DFC to an AMB to this date. In order to apply the DFC to an AMB, a star-point driving approach for AMBs must be developed beforehand. A star-connected driving approach, capable of driving a four-phase AMB, is proposed and validated against traditional H-bridges in a simulation. Further, the strategy is tested in a physical application and generalised for 4∗n phases. In terms of current dynamics, the simulation results can be compared to the well-known full H-bridge driving. The experiments on the physical application show that the actual current in the coils follows a reference with satisfactory accuracy. Moreover, the inductance measurements of the coils show a strong dependency on the rotor’s position, which is crucial for sensorless operation. A star-point connection delivers a satisfying response behaviour in an AMB application, which makes sensorless techniques that require a star point, such as the DFC, applicable to active magnetic bearings.

Due to their unique properties, like no mechanical contact and therefore no wear and no lubrication needed, Active Magnetic Bearings (AMBs) have been a dynamic field of research in the past decades. The high non-linearities of AMBs generate many challenges for the control of the otherwise unstable system, thus they need to be addressed to deliver the performance that modern applications require. Integrating the current controller dynamics into the model of a position controller in a cascading control loop helps to improve the performance of the control loop compared to a plain current controlled schema. Further, this nested control loop guarantees the predefined current dynamics of the current controller, tuned according to an industrial criterion. The systems dynamics are modelled and the proposed controller is validated experimentally on a physical test bench. The experimental results show a performant position control with a nested and explicit current controller on an AMB, even with a large air gap and star-connected coils. The trajectory range of the rotor was reduced by 87% to ±20 μm, compared to a plain current-controlled model. The proposed control strategy lays the foundation for further research, especially concerning sensorless position estimation techniques since these usually have limited bandwidth and benefit from a predefined current dynamic.