CN114062910A - Motor online diagnosis system and method - Google Patents
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Abstract
The invention relates to a motor on-line diagnosis system, which comprises a signal acquisition system, a signal processing system and a state evaluation system, wherein the signal acquisition system is used for acquiring a signal; the signal acquisition system is used for acquiring working voltage and working current signals of the motor and forming a signal package file to be sent to the signal processing system; the signal processing system is used for identifying, reading and processing fault characteristic signal files in the signal package file to form a data file and establish a database; the state evaluation system is used for further analyzing and calculating the database file to obtain the amplitude, the frequency and the phase of the motor fault components, comparing the amplitude, the frequency and the phase of the motor fault components with the corresponding values of the historical fault components of the motor, judging the health state of the motor and obtaining an evaluation result. The motor online diagnosis system provided by the invention can accurately and effectively predict the healthy state of the motor.
Description
Technical Field
The invention relates to the technical field of motor operation and maintenance, in particular to a motor online diagnosis system and method.
Background
Traditional motor maintenance strategy: based on relay protection as a rear shield, preventive maintenance is mainly used, and defective maintenance is assisted. For many years, despite the fact that preventive maintenance is strictly performed according to relevant standards, motor failures have been caused due to differences in manufacturing standards and operating environments of motors. Typical deficiencies of this maintenance strategy are: taking time as a basis: the inspection and maintenance time is fixed with the project; maintenance is insufficient: the probability of equipment damage is increased due to the over-term maintenance; and thirdly, excessive maintenance: maintenance activities bring risks and waste; fourthly, the planning performance is poor; great fault loss.
Some enterprises are beginning to consider predictive maintenance solutions for more valuable electrical machines. Such as adding routine inspection tasks for engineers or adding intrusive online status monitoring probes. The invasive monitoring mode of installing a large number of special signal acquisition probes or transmitters and the like can realize real-time monitoring of various states of equipment and environment. These probes need to be mounted on the motor windings, bearings or accessory structures and will have some additional effect on the motor. For example: on one hand, the compact structure or rigidity of the motor is easily influenced; on the other hand, the severe environment may affect the accuracy of the collected signals or the normal operation of the collecting device, thereby affecting the monitoring effect on the motor. In addition, these signal acquisition devices must be installed in situ on the motor, and for motors in inaccessible areas, these signal acquisition probes will not be able to accurately and reliably transmit the acquired signals to the analysis equipment due to the harsh environment.
Disclosure of Invention
Therefore, it is necessary to provide a motor online diagnosis system and method for accurately and effectively predicting the health state of a motor and improving the operation and maintenance strategy of the motor, aiming at the problem that the existing online motor online maintenance cannot accurately and effectively predict the health state of the motor.
In order to achieve the above purpose, the invention provides the following technical scheme:
an online motor diagnosis system comprises a signal acquisition system, a signal processing system and a state evaluation system;
the signal acquisition system is used for acquiring working voltage and working current signals of the motor and forming a signal package file to be sent to the signal processing system;
the signal processing system is used for identifying, reading and processing fault characteristic signal files in the signal package file to form a data file and establish a database;
the state evaluation system is used for further analyzing and calculating the database file to obtain the amplitude, the frequency and the phase of the motor fault waveform component, comparing the amplitude, the frequency and the phase of the motor fault waveform component with the corresponding value of the historical fault component of the motor, judging the health state of the motor and obtaining an evaluation result.
Furthermore, the signal acquisition system is connected with a traditional relay protection loop cable of the motor to acquire working voltage and working current signals of the motor.
Further, the signal processing system processes the fault characteristic signal file in the signal package file and comprises digital display, waveform display, FFT analysis, wavelet analysis, fundamental wave spectrum analysis, decibel analysis, storage and sampling rate adjustment.
Further, the motor fault characteristic signal comprises a three-phase instantaneous power average value p3(t), the characteristic frequency of the motor rotor fault and the negative sequence component of the motor stator winding fault.
Further, said p3(t) is calculated according to the following formula:
in the formula uAB、uBC、uCAIs the line voltage of the motor, according to the working voltage u of the motora、ub、ucCalculating to obtain; i.e. iA、iB、iCFor line current of the motor, according to the operating current i of the motora、ib、icAnd (4) calculating.
Further, the characteristic frequency of the motor rotor fault is the fundamental frequency f1M rotor rotation frequency frAnd m is a natural number.
Further, the motor rotor faults comprise motor rotor broken bars and air gap composite eccentric faults; the characteristic frequency of the broken bars of the motor rotor is ksf1，ksDegree of static eccentricity, f1Is the fundamental frequency; said air gap compounding the eccentric faultCharacteristic rotation angular frequency of m omegar＝m(1-s)ω1/p；ω1For stator angular frequency of rotation, of magnitude 2 π f1；ωrIs the angular frequency of rotation of the rotor, with a magnitude equal to 2 pi fr，frIs the rotation frequency.
Further, the electronic stator fault includes a negative sequence component of the motor stator turn-to-turn short circuit winding fault.
Further, the state evaluation system calculates the amplitude of the fault component of the motor according to the following formula:
in the formula, p3(t) is the three-phase instantaneous power average value p3(t)，Up1In order to be the fault voltage of the motor,
as a component of the fundamental wave,
the negative sequence component is superposed when the turn-to-turn short circuit of the motor stator occurs,
is a characteristic component of motor rotor broken bar with characteristic frequency of ksf1，
Is a characteristic component of air gap composite eccentric fault and has a characteristic rotation angular frequency of m omegar＝m(1-s)ω1/p。
Further, the fault component amplitude with the existing measurement standard is based on the existing evaluation standard; for fault component amplitude values without the existing measurement standard, a reference database is determined according to historical fault component amplitude values of the motor, a basic suggested alarm value and a shutdown overhaul value need to be set by using an offline detection result during first commissioning, and then the suggested alarm value and the shutdown overhaul value can be perfected and improved by using artificial intelligence deep learning, so that the evaluation on the health state of the motor is more accurate and effective.
An online motor diagnosis method comprises the following steps:
1. collecting working voltage and working current signals of a motor and forming a signal package file;
2. identifying, reading and processing fault characteristic signal files in the signal package file to form a data file and establish a database;
3. and further analyzing and calculating the database file to obtain the amplitude, the frequency and the phase of the motor fault components, comparing the amplitude, the frequency and the phase of the motor fault components with the corresponding values of the historical fault components of the motor, judging the health state of the motor, and obtaining an evaluation result.
The invention has the beneficial technical effects that:
the motor online diagnosis system and the motor online diagnosis method are based on the traditional relay protection circuit of the traditional motor, and take the starting point of not influencing the structures of the traditional system and equipment, realize the aims of remote diagnosis and predictive maintenance of the health state of the motor, and ensure the health state of the motor to be known and controllable.
Drawings
FIG. 1 is a schematic flow chart of the motor online diagnosis system of the present invention for online motor diagnosis;
fig. 2 is a schematic structural diagram of a signal acquisition system.
Detailed Description
The invention is described in further detail below with reference to the figures and the detailed description.
When the motor is normally designed and manufactured, the theory symmetry of the three-phase winding is required. Therefore, under the action of the three-phase symmetrical power supply, the three-phase current of the motor which normally and stably runs is symmetrical.
Three-phase synthesized fundamental wave magnetomotive force f1The expression (θ, t) is:
three-phase synthesized harmonic magnetomotive force fvThe expression (θ, t) is:
wherein v is the harmonic order, p is the number of magnetic poles, and N1Number of turns of wire set, kw1As coefficient of fundamental line group, kwvIs the harmonic line group coefficient, k is a natural number,
is three-phase current, and theta is a three-phase current symmetrical angle.
For symmetrical three-phase current
The following conclusions can be drawn:
when the harmonic frequency v is 6k-3, the harmonic magnetomotive force is 0;
when the harmonic frequency v is 6k-1, the harmonic magnetomotive force is opposite to the fundamental magnetomotive force and is called as reverse magnetomotive force;
when the harmonic number v is 6k +1, the harmonic magnetomotive force is the same as the fundamental magnetomotive force, and is called as the positive rotation magnetomotive force.
Due to the harmonic magnetomotive force, additional losses, vibrations and noise will be caused in the ac motor, and harmful additional torque will also be generated for the induction motor, deteriorating its performance. Therefore, during actual design, distributed and short-moment windings are adopted to weaken the influence of harmonic magnetomotive force, so that the motor runs stably under normal symmetrical voltage, and the additional loss, vibration and noise are greatly reduced. Conversely, if this balance is broken once, those effects will be re-amplified.
When the motor rotor fails, if the bearing structure and the rotor fail or are abnormally mounted, air gap composite eccentricity is caused, and the air gap composite eccentricity comprises air gap dynamic and/or static eccentricity, so that balanced and stable magnetomotive force in the theoretical design of the motor is broken through. This unbalance has little effect on the fundamental magnetomotive force, but severely degrades the balance of the harmonic magnetomotive force. The most direct manifestations are the abnormal increase of additional losses, vibrations and noise. The traditional fault diagnosis methods for vibration measurement, temperature measurement, noise measurement and the like are just judged by taking the fault characteristic signals as the fault characteristic signals, so that the measured fault characteristic quantities are not the most direct signal sources, but are characteristic signals after energy conversion, the characteristic information is easy to lose, and meanwhile, the fault characteristic quantities are also interfered by the limitation of the precision of a measuring instrument and the noise introduced from the outside.
Assuming that the air gap length δ (θ, t) at compound eccentricity is:
delta (theta, t) two deltam[1-ks cosθ-kd cos(ωrt-θ)]
In the formula, deltamIs the average air gap length, ksDegree of static eccentricity, kdTo dynamic degree of eccentricity, omegarAnd the rotation angular frequency of the rotor is (1-s) omega/p, the three-phase current symmetry angle is theta, and the motor running time is t.
Theoretical analysis shows that when air gap composite eccentricity exists, fundamental frequency f can be induced in the stator winding1+/-rotor rotation frequency frCharacteristic frequency components of (1). The current of these frequencies further acts with the air gap magnetic field to generate fluctuation of the torque and the rotating speed of the motor, and the fluctuation frequency is the fundamental frequency f1M rotor rotation frequency fr(m is a natural number), which is the characteristic frequency of an eccentric fault and also the characteristic frequency of a motor rotor fault.
Simplifying the reciprocal of the air gap length delta (theta, t) in the composite eccentricity, and taking a low-order term after Fourier expansion to obtain:
in the formula (4), δmIs the average air gap length, ksDegree of static eccentricity, kdTo dynamic degree of eccentricity, omegarAnd the rotation angular frequency of the rotor is (1-s) omega/p, the three-phase current symmetry angle is theta, and the motor running time is t.
In case of failure of the stator of the machine, e.g. short-circuiting or breaking between turns or phases of the coilFailure, the symmetry of the stator windings is broken. The air gap potential generated by the stator winding becomes elliptical, which can be decomposed into a normal rotation component
And the reverse component
The two rotate at the same speed and rotate in opposite directions. Component of positive rotation
Inducing a frequency f in the stator winding1Induces a frequency sf in the rotor winding which is a multiple of the slip1The potential and current of (c). Frequency sf1The rotor magnetic potential generated by the rotor current is recorded as
And
relatively stationary. Component of inversion
The same induction of frequency f in the stator winding1But opposite phase sequence, thereby producing a negative sequence component in the stator three-phase current. The negative sequence component is therefore a fault characteristic of a stator winding fault. In the same way, when the three-phase voltage input to the motor is asymmetrical, the negative sequence component is generated when the three-phase voltage is applied to the motor with symmetrical windings.
When the fault is slight, the negative sequence component accounts for a small proportion, the damage to the motor is not serious, and the traditional relay protection allows the motor to continue to operate under the condition of small fault on the basis of ensuring the stability of equipment operation and the reliability of protection setting. For more serious short circuit fault or open circuit fault, the negative sequence protection or zero sequence protection of the relay protection will act. When the fault continues to deteriorate, the fault current of the short-circuit phase exceeds the allowance of equipment, the winding can burn the winding or an iron core due to heating, the short-circuit protection or the locked-rotor protection (main protection) is required to be triggered immediately to remove the fault, and the overcurrent or overload protection (backup protection) is delayed for preventing the motor from being overheated. In order to prevent relay protection maloperation from influencing the reliability of protection, the fault is removed only by slightly damaging the motor, which is also the aim of relay protection setting calculation.
By combining the theoretical analysis results, the further mathematical analysis on various fault working conditions of the motor can obtain a certain phase current i of the motor only containing low-order harmonic components near the fundamental waveaThe simplified expression of (c):
in the formula Ip1Positive sequence component amplitude, I, corresponding to turn-to-turn and phase-to-phase short circuit faults of motor stator windingn1The amplitude of the negative sequence component corresponding to the turn-to-turn and phase-to-phase short circuit fault of the stator winding of the motor is Ibp1Amplitude of positive sequence component corresponding to motor rotor bar breakage fault, Ibn1Amplitude of negative sequence component corresponding to motor rotor bar breakage fault, Iecp1Amplitude of the positive-sequence current component, I, corresponding to an eccentric faultecn1The magnitude of the negative sequence current component corresponding to the eccentricity fault;
is Ip1The initial phase of (a) is determined,
is In1The initial phase of (a) is determined,
is Ibp1The initial phase of (a) is determined,
is Ibn1The initial phase of (a) is determined,
is Iecp1The initial phase of (a) is determined,
is Iecn1The initial phase of (a); omega1The angular frequency of rotation of the stator of the motor is equal to 2 pi f1(ii) a Omega r is the rotation angular frequency of the motor rotor and is equal to 2 pi fr；f1Is the fundamental frequency, frIs the rotation frequency.
Referring to fig. 1, the present invention provides an online motor diagnosis system, which includes a signal acquisition system, a signal processing system and a state evaluation system;
the signal acquisition system is used for acquiring working voltage and working current signals of the motor and forming a signal package file to be sent to the signal processing system;
the signal processing system is used for identifying, reading and processing fault characteristic signal files in the signal package file to form a data file and establish a database;
the state evaluation system is used for analyzing and calculating the database file to obtain the amplitude, the frequency and the phase of the fault waveform component of the motor, comparing the amplitude, the frequency and the phase of the fault waveform component of the motor with the corresponding value of the historical fault component of the motor, judging the health state of the motor and obtaining an evaluation result.
Further, referring to fig. 2, the signal acquisition system is connected with a cable of a conventional relay protection circuit of the motor to acquire working voltage and working current signals of the motor.
Further, the signal processing system processes the fault characteristic signal file in the signal package file and comprises digital display, waveform display, FFT analysis, wavelet analysis, fundamental wave spectrum analysis, decibel analysis, storage and sampling rate adjustment.
Further, the motor fault characteristic signal comprises a three-phase instantaneous power average value p3(t), the characteristic frequency of the motor rotor fault and the negative sequence component of the electronic stator winding fault.
Further, said p3(t) is calculated according to the following formula:
in the formula uAB、uBC、uCAIs the line voltage of the motor, according to the working voltage u of the motora、ub、ucCalculating to obtain; i.e. iA、iB、iCFor line current of the motor, according to the operating current i of the motora、ib、icAnd (4) calculating.
Further, the characteristic frequency of the motor rotor fault is the fundamental frequency f1M rotation frequency frAnd m is a natural number.
Further, the motor rotor faults comprise motor rotor broken bars and air gap composite eccentric faults; the characteristic frequency of the broken bars of the motor rotor is ksf1Ks is the degree of eccentricity, f1Is the fundamental frequency; the characteristic rotation angular frequency of the air gap composite eccentric fault is m omegar＝m(1-s)ω1/p；ω1For stator angular frequency of rotation, of magnitude 2 π f1；ωrIs the angular frequency of rotation of the rotor, with a magnitude equal to 2 pi fr，frIs the rotation frequency.
Further, the electronic stator fault includes a negative sequence component of the motor stator turn-to-turn short circuit winding fault.
Further, the state evaluation system calculates the amplitude of the fault component of the motor according to the following formula:
in the formula, p3(t) is the three-phase instantaneous power average value p3(t)，Up1In order to be the fault voltage of the motor,
as a component of the fundamental wave,
the negative sequence component is superposed when the turn-to-turn short circuit of the motor stator occurs,
the characteristic component of the motor rotor bar, its characteristic frequency ksf1,
is a characteristic component of the air gap composite eccentric fault, and the frequency of the characteristic angle is m omegar＝m(1-s)ω1/p，Ip1Positive sequence component amplitude, I, corresponding to turn-to-turn and phase-to-phase short circuit faults of motor stator windingn1The amplitude of the negative sequence component corresponding to the turn-to-turn and phase-to-phase short circuit fault of the stator winding of the motor is IbpkAmplitude of positive sequence component corresponding to motor rotor bar breakage fault, IbnkAmplitude of negative sequence component corresponding to motor rotor bar breakage fault, IecpmAmplitude of the positive-sequence current component, I, corresponding to an eccentric faultecnmThe magnitude of the negative sequence current component corresponding to the eccentricity fault;
is Ip1The initial phase of (a) is determined,
is In1The initial phase of (a); omega1Is a stator rotation angle with a magnitude equal to 2 pi f1；ωrIs the rotor rotation angle and has the size equal to 2 pi fr；f1Is the fundamental frequency, frIs the rotation frequency; ks is the eccentricity degree, and t is the motor running time; beta is abpk、βbnk、βecpm、βecnmAre respectively current Ibpk、Ibnk、Iecpm、IecnmThe initial phase of (c).
Further, the fault component amplitude with the existing measurement standard is based on the existing evaluation standard; for fault component amplitude values without the existing measurement standard, a reference database is determined according to historical fault component amplitude values of the motor, a basic suggested alarm value and a shutdown overhaul value need to be set by using an offline detection result during first commissioning, and then the suggested alarm value and the shutdown overhaul value can be perfected and improved by using artificial intelligence deep learning, so that the evaluation on the health state of the motor is more accurate and effective.
The invention also provides an online motor diagnosis method, which comprises the following steps:
1. collecting working voltage and working current signals of a motor and forming a signal package file;
2. identifying, reading and processing fault characteristic signal files in the signal package file to form a data file and establish a database;
3. and further analyzing and calculating the database file to obtain the amplitude, the frequency and the phase of the motor fault components, comparing the amplitude, the frequency and the phase of the motor fault components with the corresponding values of the historical fault components of the motor, judging the health state of the motor, and obtaining an evaluation result.
The motor on-line diagnosis system and the motor on-line diagnosis method are used for carrying out simulation analysis on the following fault working conditions of a prototype, and extracting simulation tests of components of each characteristic frequency of three-phase transient average power under various working conditions. Because of the test of the turn-to-turn short circuit of the motor stator, the prototype can be directly damaged, the simulation is not introduced, and only three fault conditions of normal + eccentricity of the rotor conducting bar, 1 broken bar + eccentricity of the rotor and 2 broken bars + eccentricity of the rotor are tested:
three-phase instantaneous power average value p3(t) statistics of the primary fault component amplitudes are given in Table 1 below.
TABLE 1 three-phase instantaneous power mean value p3(t) statistics of amplitude of principal fault components
From the results of prototype tests, only eccentric fault conditions exist for normal and unbroken rotor bars: makingIs k fr＝k*(1-s)f1The characteristic frequency of the eccentric fault is used as the/p (k is a natural number), and the accuracy and the effectiveness of the motor online diagnosis system and the motor online diagnosis method are proved;
for rotor bar breakage, overlapping eccentric fault conditions: the k is used as the characteristic frequency (k is taken as a natural even number) of the broken bar fault of the sf1, so that the motor online diagnosis system and the motor online diagnosis method are accurate and effective;
and the more the frequency at or near the characteristic frequency, the more apparent it is in the spectral band, otherwise it is annihilated due to the weaker power.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the present invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (11)
1. The motor online diagnosis system is characterized by comprising a signal acquisition system, a signal processing system and a state evaluation system;
the signal acquisition system is used for acquiring working voltage and working current signals of the motor and forming a signal package file to be sent to the signal processing system;
the signal processing system is used for identifying, reading and processing fault characteristic signal files in the signal package file to form a data file and establish a database;
the state evaluation system is used for analyzing and calculating the database file to obtain the amplitude, the frequency and the phase of the fault waveform component of the motor, comparing the amplitude, the frequency and the phase of the fault waveform component of the motor with the corresponding value of the historical fault component of the motor, judging the health state of the motor and obtaining an evaluation result.
2. The on-line motor diagnosis system of claim 1, wherein the signal acquisition system is connected with a conventional relay protection loop cable of the motor and acquires the working voltage and working current signals of the motor.
3. The on-line motor diagnostic system of claim 1 wherein the signal processing system processes the fault signature file in the signal package file including digital display, waveform display, FFT analysis, wavelet analysis, fundamental spectrum analysis, decibel analysis, storage, sample rate adjustment.
4. The motor online diagnostic system of claim 1, wherein the motor fault signature comprises a three-phase instantaneous power average p3(t), the characteristic frequency of the motor rotor fault and the negative sequence component of the motor stator winding fault.
5. The online motor diagnosis system of claim 4, wherein p is the number of p3(t) is calculated according to the following formula:
in the formula uAB、uBC、uCAIs the line voltage of the motor, according to the working voltage u of the motora、ub、ucCalculating to obtain; i.e. iA、iB、iCFor line current of the motor, according to the operating current i of the motora、ib、icAnd (4) calculating.
6. The online motor diagnosis system of claim 4, wherein the characteristic frequency of the motor rotor fault is a fundamental frequency f1M rotor rotation frequency frAnd m is a natural number.
7. The online motor diagnosis system of claim 6, wherein the motor rotor fault comprises a motor rotor breakBar and air gap compound eccentricity faults; the characteristic frequency of the broken bars of the motor rotor is ksf1，ksDegree of static eccentricity, f1Is the fundamental frequency; the characteristic rotation angular frequency of the air gap composite eccentric fault is m omegar＝m(1-s)ω1/p；ω1For stator angular frequency of rotation, of magnitude 2 π f1；ωrIs the angular frequency of rotation of the rotor, with a magnitude equal to 2 pi fr，frIs the rotation frequency.
8. The online motor diagnosis system according to claim 4, characterized in that the electronic stator fault comprises a negative sequence component of a motor stator turn-to-turn short circuit winding fault.
9. The system of claim 1, wherein the condition evaluation system calculates the magnitude of the fault component of the motor according to the following formula:
in the formula, p3(t) is the three-phase instantaneous power average value p3(t)，Up1In order to be the fault voltage of the motor,
as a component of the fundamental wave,
the negative sequence component is superposed when the turn-to-turn short circuit of the motor stator occurs,
is a characteristic component of motor rotor broken bar with a characteristic frequency of ksf1，
Compounding eccentric faults for air gapsCharacteristic component of (a) having a characteristic rotation angular frequency of m ωr＝m(1-s)ω1/p。
10. The on-line motor diagnosis system according to any one of claims 1 to 9, wherein the fault component amplitude value with a ready-made standard is based on a ready-made evaluation standard; for the fault component amplitude without the existing measurement standard, a reference database is determined according to the historical fault component amplitude of the motor, the basic recommended alarm value and the shutdown overhaul value need to be set by using an offline detection result during the first commissioning, and the recommended alarm value and the shutdown overhaul value can be perfected and improved by using artificial intelligence deep learning subsequently.
11. An online motor diagnosis method is characterized by comprising the following steps:
step 1, collecting working voltage and working current signals of a motor and forming a signal package file;
step 2, identifying, reading and processing fault characteristic signal files in the signal package file to form data files and establish a database;
and 3, further analyzing and calculating the database file to obtain the amplitude, the frequency and the phase of the motor fault component, comparing the amplitude, the frequency and the phase of the motor fault component with the corresponding value of the historical fault component of the motor, judging the health state of the motor, and obtaining an evaluation result.
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| CN102135600A (en) * | 2011-01-28 | 2011-07-27 | 中国人民解放军海军潜艇学院 | Fault detection device and method of asynchronous motor |
| CN104166095A (en) * | 2014-08-29 | 2014-11-26 | 东南大学 | Fault information fusion diagnosis method based on double-edge linear motor |
| CN113514776A (en) * | 2020-04-09 | 2021-10-19 | 中车株洲电力机车研究所有限公司 | Interturn short circuit fault diagnosis method, device and equipment of asynchronous motor |
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| CN117214589A (en) * | 2023-11-08 | 2023-12-12 | 天津德科智控股份有限公司 | EPS system time domain response field test method |
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