Design, Verification and Validation of DSLIM

based Electro-Magnetic Launch System with

UCPPS

Kamal Gupta Arbind Kumar Himanshu Gupta

2022 IEEE International Conference on Power Electronics, Drives and Energy Systems (PEDES) | 978-1-6654-5566-4/22/$31.00 ©2022 IEEE | DOI: 10.1109/PEDES56012.2022.10080595

Electro-Mechanical Systems Group Electro-Mechanical Systems Group Electro-Mechanical Systems Group

Research & Development Estt. (Engrs)
Defence Research and Dev. Orgn.
Ministry of Defence, GOI,
Dighi Post, Pune, India
kamalgupta020@gmail.com
Research & Development Estt. (Engrs)
Defence Research and Dev. Orgn.
Ministry of Defence, GOI,
Dighi Post, Pune, India
arbindmani@gmail.com
Research & Development Estt. (Engrs)
Defence Research and Dev. Orgn.
Ministry of Defence, GOI,
Dighi Post, Pune, India
himpop@gmail.com

Abstract— Electrical Motors are best suitable for Defence
application as electrical motors are maintenance free, reliable
compare to hydraulic motors etc. Electrical motors are also
suitable to make all electric systems. Among the various type of
motor, Linear Electric Motors (LEM) are preferred choice for
translational motion like accelerating an Unmanned Aerial
Vehicle to make it fly or accelerating a missile for launching.
Among various types of Linear Electric Motors, moving
primary and static secondary Double-Sided Linear Induction
Motor (DSLIM) is best suitable for few hundred-kilogram
payload considering the cost, power, weight, volume,
development time etc. In this paper, design verification &
validation of DSLIM based Electro-Magnetic Launch System
(EMLS) with Ultra-Capacitor based Pulse Power Source
(UCPPS) as an input power source is presented for launching a
dummy payload of 100 kg. Design optimization and verification
is conducted in ANSYS MAXWELL software. Design
validation is conducted by testing and trials on realized system
hardware.
Keywords— Double Sided Linear Induction Motor (DSLIM),
Ultra Capacitor based Pulse Power Source (UCPPS), Linear
Electric Motor (LEM), Electro Magnetic Launch System (EMLS),
Rotary Induction Motors (RIM), Rotary Electric Motors (REM),
Linear Induction Motor (LIM), Variable Voltage Variable
Frequency (VVVF) Drive.
I. INTRODUCTION
Nicola Tesla invented Rotary Induction Motor (RIM) in
year 1889. Now RIMs are more reliable, efficient and widely
used in industry for rotary motion application. Attempts are
made to use RIM with gear box and actuator for linear motion
application since its invention. But this reduces the system
reliability and restrict the linear speed. So now there is a trend
to modify RIM for linear motion i.e. Linear Induction Motor
(LIM). Among the various types of LIM, moving primary and
static secondary Double Sided LIM (DSLIM) is best suitable
for few hundred kilogram payload considering the cost,
power, weight, volume, development time etc. This type of
Electro-Magnetic Launch System (EMLS) is also suitable for
accelerating Unmanned Aerial Vehicle (UAV) and Missiles
for its launching. EMLS system needs 200-300 kJ energy in
pulse power form for few seconds. To fulfill the EMLS power
requirement, huge Conventional power source is required. But
now due to the advancement in the ultra-capacitor technology,
Ultra-Capacitor based Pulse Power Source (UCPPS) has been
realized to meet the EMLS power requirement. UCPPS takes
few kW electric power from conventional sources for its
charging. After charging, UCPPS can generate pulse power
for EMLS application.
Development of DSLIM based EMLS system for 100 kg
payload is given in [1]. Basic design equations used are given
in [30]. Equations given in [30] are also used for design and
development of Tubular Linear Induction Motor (TLIM)
given in [2]. E. R. Laithwaite, S. A. Nasar and J.F. Gieras are
the few pioneered is the field of Linear Induction Motors and
the references are given [3]-[29]. In this paper, development
of Ultra-Capacitor based Pulse Power Source (UCPPS) is
presented. Design verification & validation of DSLIM based
EMLS with UCPPS as an input power source is also
presented. Design optimization and verification is conducted
in MAXWELL software. Design validation is conducted by
testing and trials on realized system hardware.
II. BRIEF OF DSLIM BASED EMLS
Complete system consists of 13-meter-long moving
primary and static secondary DSLIM, UCPPS & Variable
Voltage Variable Frequency (VVVF) drive. It is grouped into
four major blocks; namely, Launch Motor, Launch Controller,
Power Conversion Electronics, Energy generation & storage
system. The EMLS consists of Double-Sided linear Induction
Motor which consists of two stators that have the function of
a conventional motor’s armature. EMLS system is shown
Fig.1.
During launch, the power conversion subsystem releases
the stored energy from the energy storage device using Power
Conditioning Units. The Power Conditioning Unit provides a
controlled rising frequency and voltage to the DSLIM.

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Operator controls the power through a closed loop
system. Proximity sensors on the track monitor its operation,
allowing the system to ensure that it provides the desired
acceleration. The closed loop system allows the EMLS to
maintain a constant tow force, which helps reduce the launch
stresses on the UAV’s / dummy airframe. The dummy payload
is placed over the slider structure. The slider structure is
supported over the LM rails. The LM rails are mounted over
the stator of the linear motor. LM rail helps to guide the slider
structure in forward and reverse direction. As the motor is
energized, the rotor beings to move linearly within the stator
which in turn enables the slider structure to slide over the LM
rails. Power scheme of the system is shown in Fig.2.
Inductive type proximity sensors are fitted at secondary
every one metre distance to detect the mover position and
speed. System provides electrical braking after achieving the
desired launch speed. System is also having mechanical
braking system at the end. Mechanical braking system is
provided for system reliability in case of power or subsystem
failure during the launch operation.
III. BRIEF OF UCPPS
There is a high-power requirement for few seconds. This
power demand cannot be fulfilled by conventional mobile
power sources due to its limitations. So, energy storage
system is essential. Ultra-Capacitor Bank is most suitable at
this power level. SkeletonTM Ultra-Capacitor Cell is selected
due to its extreme power density. One cell consists of 3200F,
2.85 V, diameter 60.2 mm, length 138 mm. Further details
can be seen at [31]. This is shown in Fig. 3(a). Thirty-six such
cells are connected in series to make a commercially
available module SkelMod102V88F as shown in Fig. 3(b).
Dimension of the module are 486 × 449 × 152 mm and having
a total mass of 26.5 kg. Further details can be seen at Fig.4.
Eight such modules are further connected in series to make it
an Ultra-Capacitor bank. Two such Ultra-Capacitor banks are
used for this application.
Ultra-Capacitor banks are charged in parallel using a
commercially available charger and it takes about 18 minutes
to charge to a voltage of 760 V. Entire charger and Ultra-
Capacitor bank is shown in Fig. 4. Ultra-Capacitor Bank
voltage is selected so that it can match with the drive DC link
voltage. An inverter output voltage is directly feeding to
mobile primary (Stator) through flexible cable arrangement.
The capacity of the inverter is 200 kVA and three options are
available to the user: manual control, Vector control or DTC.
Since the drive is developed for conventional rotary motor,
necessary design changes have been made to use it for this
application to minimise the development time.
IV. DESIGN OPTIMISATION AND VERIFICATION
3-D MAXWELL software is used for design optimisation
and verification of EMLS. SIMPLORER software is used for
modelling and simulation of UCPPS and drive. Model of
complete system is shown in Fig.5. Since the actual system
consists of filter at output of the inverter, in order to simulate
the same in the SIMPLORER, it has been selected as true sine
wave output at output of the inverter. Voltage and Frequency
have been optimised and set manually in SIMPLORER to get
constant acceleration.
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Simulation results are shown from Fig.6 to Fig.10. VVVF
generated by inverter of the drive is applied to DSLIM as
shown in Fig.6. Accordingly, current drawn by the DSLIM
and thrust generated by DSLIM is shown in Fig.7 & 8
respectively. Fig. 9 & Fig.10 shows the mover speed and
position with respect to time. Validation of the design &
simulation results has been carried out on the realised system.
V. CONCLUSION
In this paper, Design Verification and Validation of
DSLIM based Electro-Magnetic Launch System with UCPPS
has been presented. Analytical design optimization &
verification of complete system has been carried out by
modelling and simulation using ANSYS MAXWELL
software. further design validation is completed by realizing
hardware, system integration, testing & trials.
Authors are publishing their research work in IEEE Power
Electronics, Drives and Energy Systems Conferences
(PEDES) [1], [2] and [30] since last three conferences and
same with its detailed experimental work will be presented in
its future Conferences.
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[31] Online available at: https://www.skeletontech.com/skelmod-102v-
ultracapacitor-module

Fig. 1: EMLS

Fig. 2: EMLS Power scheme

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Fig. 3(a): Skelcap3200 Cell Fig. 3(b): SkelMod102V88F

Fig. 4: Ultra-Capacitor Bank for Pulse Power Source

Fig. 5: Model of complete system

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 Fig. 6: Input voltage to DSLIM (X-axis: Time in Second, Y-axis: Voltage in Volts)

Fig. 7: Input current to DSLIM (X-axis: Time in Second, Y-axis: Current in Amps)

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 Fig. 8: Thrust developed by DSLIM (X-axis: Time in Second, Y-axis: Thrust in kN)

Fig. 9: Mover Speed (X-axis: Time in Second, Y-axis: Speed in m/s)

Fig. 10: Mover Position (X-axis: Time in Second, Y-axis: Position in m)

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