Estimation of frequency components in stator current for the detection of broken rotor bars in induction machines

The limitation of data window length in induction machine broken rotor bar diagnostics is a real challenge in practice. Sideband frequencies which are used as broken rotor bar indicators are very close to the fundamental frequency and have low magnitude. Traditional spectral analysis approach such as Discrete Fourier Transform (DFT) can be inaccurate in these conditions due to its inherent drawbacks such as the requirement of long data window for high resolution and the side lobe leakage in frequency domain. In this paper, a high-resolution spectral analysis technique, Prony Analysis (PA), is proposed for broken rotor bar detection in induction machines. The method is described and demonstrated in detail, validated by experimental data, and compared with DFT. Results clearly indicate the advantages of PA over DFT in terms of maintaining a high resolution with a much shorter window and a better frequency estimate accuracy with the same window length.     

摆线齿轮泵内转子加工工艺及工装设计

摆线转子泵具有体积小、结构紧凑、零件少、重量轻、噪声低、工作平稳、自吸性强及良好的高转速特性等特点,广泛用于纺机、印机、机床、轻工机械等需低压连续润滑或间断供油润滑的机械设备上.分析了内转子齿廓为短幅外摆线圆内等距线,而不宜采用普通外摆线及长幅外摆线的原因,确定了磨削参数、机床的改装方法及专用工艺装备.     

高速微孔钻床主轴系统的动态特性分析

依据转子动力学理论,利用Timoshenko粱轴理论,建立了包含旋转惯性力、陀螺力矩、离心力、弯曲变形、扭转变形、钻削轴向力和钻头的三种边界条件在内的高速微孔钻床主轴系统动力学模型。在利用实验和现有文献对所建立的模型进行了检验的基础上,对高速微孔钻床主轴系统的临界转速、临界轴向压力进行了分析。结果表明高速微孔钻床主轴系统的临界转速随钻削轴向压力的增大而减小,并且钻削过程中比刚入钻时能承受更高的转速,更大的轴向力;临界轴向压力随高速微孔钻床主轴系统转速的升高而降低,即随着钻削转速的提高,应适当减小钻削轴向力。     

Detection of a static eccentricity fault in a closed loop driven induction motor by using the angular domain order tracking analysis method

In this study, a new method was presented for the detection of a static eccentricity fault in a closed loop operating induction motor driven by inverter. Contrary to the motors supplied by the line, if the speed and load, and therefore the amplitude and frequency, of the current constantly change then this also causes a continuous change in the location of fault harmonics in the frequency spectrum. Angular Domain Order Tracking analysis (AD-OT) is one of the most frequently used fault diagnosis methods in the monitoring of rotating machines and the analysis of dynamic vibration signals. In the presented experimental study, motor phase current and rotor speed were monitored at various speeds and load levels with a healthy and static eccentricity fault in the closed loop driven induction motor with vector control. The AD-OT method was applied to the motor current and the results were compared with the traditional FFT and Fourier Transform based Order Tracking (FT-OT) methods. The experimental results demonstrate that AD-OT method is more efficient than the FFT and FT-OT methods for fault diagnosis, especially while the motor is operating run-up and run-down. Also the AD-OT does not incur any additional cost for the user because in inverter driven systems, current and speed sensor coexist in the system. The main innovative parts of this study are that AD-OT method was implemented on the motor current signal for the first time.     

A new diagnosis of broken rotor bar fault extent in three phase squirrel cage induction motor

This paper proposes a new induction motor broken bar fault extent diagnostic approach under varying load conditions based on wavelet coefficients of stator current in a specific frequency band. In this paper, winding function approach (WFA) is used to develop a mathematical model to provide indication references for parameters under different load levels and different fault cases. It is shown that rise of number of broken bars and load levels increases amplitude of the particular side band components of the stator currents in faulty case. Stator current, rotor speed and torque are used to demonstrate the relationship between these parameters and broken rotor bar severity. An induction motor with 1, 2 and 3 broken bars and the motor with 3 broken bars in experiment at no-load, 50% and 100% load are investigated. A novel criterion is then developed to assess rotor fault severity based on the stator current and the rotor speed. Simulations and experimental results confirm the validity of the proposed approach.     

An investigation of the effects of measurement noise in the use of instantaneous angular speed for machine diagnosis

In order to discriminate small changes for early fault diagnosis of rotating machines, condition monitoring demands that the measurement of instantaneous angular speed (IAS) of the machines be as accurate as possible. This paper develops the theoretical basis and practical implementation of IAS data acquisition and IAS estimation when noise influence is included. IAS data is modelled as a frequency modulated signal of which the signal-to-noise ratio can be improved by using a high-resolution encoder. From this signal model and analysis, optimal configurations for IAS data collection are addressed for high accuracy IAS measurement. Simultaneously, a method based on analytic signal concept and fast Fourier transform is also developed for efficient and accurate estimation of IAS. Finally, a fault diagnosis is carried out on an electric induction motor driving system using IAS measurement. The diagnosis results show that using a high-resolution encoder and a long data stream can achieve noise reduction by more than 10 dB in the frequency range of interest, validating the model and algorithm developed. Moreover, the results demonstrate that IAS measurement outperforms conventional vibration in diagnosis of incipient faults of motor rotor bar defects and shaft misalignment.     

Parameter identification and slip estimation of induction machine

This paper presents a newly developed algorithm for induction machine rotor speed estimation and parameter detection. The proposed algorithm is based on spectrum analysis of the stator current. The main idea is to find the best fit of motor parameters and rotor slip with the group of characteristic frequencies which are always present in the current spectrum. Rotor speed and parameters such as pole pairs or number of rotor slots are the results of the presented algorithm. Numerical calculations show that the method yields very accurate results and can be an important part of machine monitoring systems.     

基于旋转变压器的直升机旋翼转速信号变换器设计

为克服传统旋翼转速变换器硬件结构复杂、功能扩展困难和低转速采集灵敏度低和精度差的缺点,采用旋转变压器替代原磁感应器件作为转速传感器,以AD2S1210旋转变压器数字变换器和STM32F103处理器为核心,设计实现一种新型的转速信号变换器。经验证,设计满足了系统指标要求,方便功能扩展,系统精度及可靠性得到提高,具有较高的工程应用参考价值。     

无轴承永磁同步电机转子速度自检测复合方法研究

针对单一转速估计方法难以实现全速范围内准确估计转子速度的缺陷,提出一种转速估计复合方法,即在零速及低速运行时,采用脉振高频信号注入法。该方法不依赖于电机模型参数而仅依赖于电机本身的凸极特性,可实现零速及低速时转子速度的准确估计;高速运行时,采用带多重次优渐消因子扩展卡尔曼滤波器（SMFEKF）进行转速估计,利用SMFEKF极强的模型失配鲁棒性和独特的强跟踪能力,有效地提高系统在稳态及突变状态下的跟踪性能。通过设计两种方法的“软切换”,实现低速到高速的平滑切换,并将该复合方法在无轴承永磁同步电机无速度传感器矢量控制系统中进行仿真研究。仿真结果表明：该复合方法能在全速范围内实现转子速度与位置的准确估计;在系统状态突变或负载扰动时,误差更小,鲁棒性更强。     

无速度传感器转子磁场定向感应电机控制系统研究与开发

介绍了一种采用磁链和开环速度估算器的转子磁场定向的控制系统，系统设计的的关键问题是磁链的观测和速度的准确估算。按照模型参考自适应系统构造出参考模型和可调模型来实现了扩展卡尔曼滤波对磁链和电机转速的估算，并成功应用此算法设计了一套DSP实验控制系统，实现了速度自适应识别。介绍了DSP实验系统的硬件和软件实现方法并对实验结果进行了分析。模型试验应用于1．0kW的感应电机取得了较好的的控制效果。     

NEURAL STATE FILTERING FOR ADAPTIVE INDUCTION MOTOR SPEED ESTIMATION

Effective sensorless transient speed estimation of induction motors is desirable for both on-line condition monitoring and assessment, and for efficiency calculations. In this paper, a sensorless neural adaptive speed filter is developed for induction motors operating under normal conditions and running off the power supply mains. The filter performance is demonstrated by comparisons with speed sensor measurements and spectral speed estimates. In addition to nameplate information required for initial filter set-up, the proposed neural speed filter uses only measured motor terminal currents and voltages. Initial training of the speed filter is accomplished off-line, using rotor slot harmonic-based speed estimates. The developed speed filter is scalable and it has been used for speed estimation of induction motors with varying power ratings. Incremental tuning is used to further improve filter performance and reduce filter development time significantly.     

Rotor drive in a balancing machine

In universal balancing machines, a frequency-controlled drive may be used to turn the component being balanced (the rotor). An algorithm is presented for the selection of a speed consistent with effective balancing.     

Automatic progressive damage detection of rotor bar in induction motor using vibration analysis and multiple classifiers

There is an increased interest in developing reliable condition monitoring and fault diagnosis systems of machines like induction motors; such interest is not only in the final phase of the failure but also at early stages. In this paper, several levels of damage of rotor bars under different load conditions are identified by means of vibration signals. The importance of this work relies on a simple but effective automatic detection algorithm of the damage before a break occurs. The feature extraction is based on discrete wavelet analysis and autocorrelation process. Then, the automatic classification of the fault degree is carried out by a binary classification tree. In each node, comparing the learned levels of the breaking off correctly identifies the fault degree. The best results of classification are obtained employing computational intelligence techniques like support vector machines, multilayer perceptron, and the k-NN algorithm, with a proper selection of their optimal parameters.     

基于全速域混合控制的同步磁阻电机无传感器矢量控制系统

针织大圆机的特殊运动状态要求其驱动电机具有较大的启动和带载能力以及较高的稳态运行精度,同步磁阻电机是一种应用于针织大圆机的理想电机,但现有同步磁阻电机无传感器控制,存在转子位置估计误差大、速度切换不平滑等问题。对此,提出一种基于全速域混合控制的同步磁阻电机无传感器矢量控制系统,零速和低速时采用脉振高频电流注入法,通过在估计坐标系的d轴注入一个幅值恰当的高频电流信号,使用估计q轴的高频电压信号估计转子位置;中速和高速时采用模型参考自适应法,通过建立数学模型并对其进行稳定性分析来估计转子位置;为了实现零速和低速到中高速的速度切换,提出一种改进的过渡区域融合观测方案,采用正弦型饱和函数代替传统的线性切换函数进行位置融合。为了验证方案的有效性,搭建了平台进行测试。由结果表明,该方案启动过程带载能力强,切换过程平滑且稳定,稳态运行过程波动小,是一种较适合大圆机电机驱动的无传感器矢量控制方法。     

A validated model for the prediction of rotor bar failure in squirrel-cage motors using instantaneous angular speed

Instantaneous angular speed (IAS)-based condition monitoring is an area in which significant progress has been achieved over the recent years. This condition monitoring technique is less known compared to the existing conventional methods. This paper presents model-predicted simulation and experimental results of broken rotor bar faults in a three-phase induction motor using IAS variations. The simulation was performed under normal, and a broken rotor bar fault. The present paper evaluates through simulating and measuring the IAS of an induction motor at broken rotor bar faults in both time and frequency domains. Experimental results show a good agreement with the model-predicted simulation results. Three vital key features were extracted from the angular speed variations. One feature is the modulating contour of pole pass frequency periods in time domain. The other two features are in frequency domain. The primary feature is the presence of the pole pass frequency component at the low-frequency region of the IAS spectrum. The secondary feature which are the multiple of pole pass frequency sideband components around the rotor speed frequency component. Experimental results confirm the validity of the simulation results for the proposed method. The IAS has demonstrated more sensitivity than current signature analysis in detecting the fault. This research also shows the power of angular speed features as a useful tool to detect broken rotor bar deteriorations using any economical transducer such as low-resolution rotary shaft encoders; which may well be already installed for process control purposes.     

Detection of combined faults in induction machines with stator parallel branches through the DWT of the startup current

The main objective of this paper is to diagnose the presence of combined faults in induction machines. For this purpose, a methodology based on the application of the Discrete Wavelet Transform (DWT) to the stator startup current is used. This approach was applied in previous works with success to the diagnosis of rotor asymmetries and mixed eccentricities in motors with different sizes and conditions. However, as most of the diagnosis methods hitherto developed, the application of the proposed approach was circumscribed to situations in which a single fault was present in the machine. In addition, the influence of other phenomena such as load torque oscillations or voltage fluctuations was studied, but without considering the combination of these phenomena and the fault in the machine. This work is intended, first, to apply the proposed transient-based methodology to several cases in which different faults (rotor asymmetries, mixed eccentricities and inter-turn and inter-coil stator short-circuits) are simultaneously present in the machine and, second, to apply it to cases regarding faults combined with other phenomena making difficult the diagnosis, such as load torque oscillations. Interesting considerations regarding the preponderance of the effects of some of the faults are also done in the paper. The application of the methodology is focused on induction machines with stator parallel branches; in this sense, the suitability of the use either of the phase current or of the branch current for the diagnosis of each particular fault is analysed. The results look promising with regard to the validity of the methodology for the reliable discrimination of simultaneous electromechanical faults and the diagnosis of faults combined with other phenomena.     

动平衡机用数字跟踪滤波器实现方法研究

电机转子轻量化、高速化的发展，给动平衡机的精度提出了更高的要求。动平衡机的精度主要取决于强背景噪声干扰下小信号的提取能力，要求滤波对信号的变化具有自适应性。提出了数字跟踪窄带滤波方法，实现的自适应跟踪方法简便，消噪效果良好。仿真和应用结果表明，该方法提高了小信号测量的精度和稳定性，减小了平衡机最小可达剩余不平衡量。     

基于异步电动机的电动汽车驱动系统

为了顺应汽车低碳环保的发展趋势,将异步电机用作电动汽车的驱动电机来代替价格昂贵且环保性差的永磁同步电机。采取转子磁链定向矢量控制的方法来实现异步电机的调速控制,在此基础上建立了一个异步电机作为驱动电机,由电池和双向DC/DC供电的电动汽车驱动系统。推导了异步电机的数学模型,搭建了一个小型电动汽车实验平台,并在实验平台上对异步电机调速性能和双向DC/DC供电系统进行了实验验证。实验结果表明,采用转子磁链定向矢量控制能很好的实现电动汽车的驱动系统的调速控制。     

A new approach to detect broken rotor bars in induction machines by current spectrum analysis

This paper deals with a new technique to detect broken rotor bars in polyphase induction machines. Like most techniques, we employ the Fourier Transform of the stator current to make detection. But where the other methods use the Fourier Transform modulus, this alternative approach proposes to analyse its phase. As shown by results, the Fourier Transform phase allows to detect one broken rotor bar when the motor operates under a low load but the method robustness decreases for a half-broken rotor bar. So, in order to improve the diagnosis and to permit the detection of incipient broken rotor bar, the analysis is completed with the Hilbert Transform. This transform provides good results and a partially broken rotor bar can be detected when the load torque is equal or greater than 25%. The main advantage of these methods is that the final decision on the rotor cage state is took without the healthy motor reference.     

A review on MRAS-type speed estimators for reliable and efficient induction motor drives

Induction machines have recently been very popular in variable-speed drives, because of their robust construction and relatively low manufacturing costs (brushless), maintenance-free and well-matured control methods. However, for high-precision control and efficiency optimization one needs the information on the rotor speed which can be measured using different speed sensors. All sensors require a mounting space and cabling, they also generate extra costs and reduce system reliability. Therefore, many of the recent research efforts have been dedicated to sensorless or encoderless electrical drives offering such considerable advantages as: lower cost, reduced size and hardware complexity of the drive system, elimination of sensor cables, lower maintenance requirements, possible operation in aggressive environment, higher noise immunity, reliable and user friendly operation. In this article all well-known sensorless techniques are shortly addressed, but the main focus is on the solutions based on the Model Reference Adaptive System (MRAS) concept. The mathematical models and schemes of all types of MRAS-type speed estimators known from the literature are gathered in this article. The comparative analysis of these speed estimators is done from the following points of view: the speed adaptation mechanism derivation based on the Lyapunov theory, stability problems near zero speed and in the regenerating operation mode, and the sensitivity of MRAS estimators to induction machine parameter changes.