WO2022107100A1 - Procédé et système d'auto-détection de défaut de moteur à induction - Google Patents

Procédé et système d'auto-détection de défaut de moteur à induction Download PDF

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Publication number
WO2022107100A1
WO2022107100A1 PCT/IB2021/060842 IB2021060842W WO2022107100A1 WO 2022107100 A1 WO2022107100 A1 WO 2022107100A1 IB 2021060842 W IB2021060842 W IB 2021060842W WO 2022107100 A1 WO2022107100 A1 WO 2022107100A1
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WO
WIPO (PCT)
Prior art keywords
frequency
fault
induction motor
amplitude
rotor
Prior art date
Application number
PCT/IB2021/060842
Other languages
English (en)
Inventor
Suriyachack ARCHWICHAI
Norased PUNYAPENG
Jarin JULABOOT
Nuttasak MUNHADEE
Wityanant THONGSAWAI
Original Assignee
Rayong Engineering And Plant Service Co., Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rayong Engineering And Plant Service Co., Ltd. filed Critical Rayong Engineering And Plant Service Co., Ltd.
Publication of WO2022107100A1 publication Critical patent/WO2022107100A1/fr

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/34—Testing dynamo-electric machines
    • G01R31/343—Testing dynamo-electric machines in operation

Definitions

  • An induction motor is considered an important machine widely used in the industrial sector, as well as various manufacturing processes.
  • the motor usually become deteriorated after several uses due to both the operation conditions and the lifespan of the motor’s components.
  • the manufacturing process will be affected, for example, the manufacturing process must be halted, or the operator may be endangered. Consequently, there is a great need for development of a method or a system to help detect the motor operation status to find out whether it is ready for use or whether there is a component malfunction in order to observe the motor and prevent damage in case of motor malfunction.
  • a general method used at present for detecting an induction motor fault involves with the use of a motor rotational speed measuring apparatus to measure the motor rotational speed in RPM unit and calculate the obtained data as a frequency composition data and analyze for a frequency that may result from malfunction of motor components.
  • Another principle for detecting an induction motor fault is to process the data of the current supplied to the motor as a frequency composition to analyze the fault in different motor components.
  • Prior arts related to the method and system for detecting an induction motor fault using the current data are as follows.
  • KR 102040397 B discloses a system for diagnosing an induction motor failure which comprises a current sensor for measuring an input current of an inverter to be used with the induction motor, a signal processor for removing high-frequency current components through a low-pass filter relative to an input current measured by the current sensor, and a signal analyzing unit for performing a fast Fourier transform (FFT) relative to a signal which is processed by the signal processor.
  • FFT fast Fourier transform
  • the signal analysis through a fast Fourier transform is performed to diagnose the motor failure.
  • the failure is diagnosed by analyzing the inverter input current for a stator winding short circuit and a rotor bar breakage, which usually occur in the induction motor.
  • US 20120001580 Al discloses a system and method for detecting a rotor fault condition in an AC induction machine.
  • the system includes a processor programmed to receive voltage and current data from an AC induction machine, generate a current frequency spectrum from the current data, and identify rotor-fault related harmonics in the current frequency spectrum.
  • the processor is also programmed to calculate a fault severity indicator using the voltage and current data, identified rotor-fault related harmonics, and motor specifications, analyze the fault severity indicator to determine a possibility of rotor fault and generate an alert based on the possibility of rotor fault.
  • US 4,965,513 discloses a method for analyzing a motor current noise signature and an apparatus for remotely monitoring operating characteristics of an electric motor-operated device such as a motor-operated valve.
  • Frequency domain signal analysis techniques are applied to a conditioned motor current signal to identify various operating parameters of the motor driven device from the motor current signature.
  • the signature may be recorded and compared with subsequent signatures to detect operating abnormalities and degradation of the device.
  • the first object of the present invention is to provide an improved method and system for detecting an induction motor fault to eliminate the limitations mentioned above which are capable of auto -detecting an induction motor fault.
  • the object of the present invention is to provide the method and system capable of auto-detecting the induction motor fault in a convenient, accurate, and reliable manner, as well as analyzing and determining the fault in motor components, e.g., whether the fault is caused by a rotor, a stator or an air gap imbalance.
  • Another object of the present invention is to provide the method and system capable of detecting the induction motor fault in an automatic and continuous manner, analyzing the fault and displaying data to keep the operator informed in real time, analyzing possible damages, and predicting an induction motor’s remaining lifespan.
  • the inventor of the present invention developed a method for auto-detecting an induction motor fault comprising measuring the current supplied to the induction motor to obtain a current signal data in a time domain, converting the current signal data in the time domain into a current signal data in a frequency domain, determining a fault frequency amplitude obtained from a calculation using a rotor speed at a rotor frequency where the amplitude is maximum in a range between induction motor’s synchronous frequency and induction motor’s full load driving frequency, determining a comparative fault frequency amplitude by determining the highest amplitude in a predetermined frequency range, and analyzing the induction motor fault by performing according to the following conditions: in a case where the highest comparative fault frequency amplitude is in the predetermined frequency range, the higher amplitude between the fault frequency amplitude obtained from the calculation and the comparative fault frequency amplitude is selected for a comparison with a predetermined fault criteria, or in a case where the highest comparative fault frequency amplitude
  • the present invention relates to a system for auto -detecting an induction motor fault
  • a current measuring device for measuring the current supplied to the induction motor to obtain a current signal data in a time domain
  • a processor provided for converting the current signal data in the time domain into a current signal data in a frequency domain, determining a fault frequency amplitude obtained from a calculation using a rotor speed at a rotor frequency where the amplitude is maximum in a range between induction motor’s synchronous frequency and induction motor’s full load driving frequency, determining a comparative fault frequency amplitude by determining the highest amplitude in a predetermined frequency range, and analyzing the induction motor fault by performing according to the conditions explained above, and a display device for displaying the data obtained from the processor.
  • Fig. 1 is a scheme showing the procedure of the method for auto-detecting the induction motor fault according to the present invention.
  • Fig. 2 is a scheme showing the procedure of the damage determination and the prediction of the induction motor’s remaining lifespan according to the present invention.
  • Fig. 3 is a scheme showing the components of the system for auto -detecting the induction motor fault according to the present invention.
  • the procedure of the method for auto-detecting the induction motor fault comprises measuring the current supplied to the induction motor to obtain the current signal data in the time domain, converting the current signal data in the time domain into the current signal data in the frequency domain, determining the fault frequency amplitude obtained from the calculation using the rotor speed at the rotor frequency where the amplitude is maximum in the range between the induction motor’s synchronous frequency and the induction motor’s full load driving frequency, determining the comparative fault frequency amplitude by determining the highest amplitude in the predetermined frequency range, and analyzing the induction motor fault by performing according to the conditions of case 1 or 2 as follows.
  • Case 1 In a case where the highest comparative fault frequency amplitude is in the predetermined frequency range, the higher amplitude between the fault frequency amplitude obtained from the calculation and the comparative fault frequency amplitude will be selected for the comparison with the predetermined fault criteria.
  • Case 2 In a case where the highest fault comparative frequency amplitude is outside the predetermined frequency range, the fault frequency amplitude obtained from the calculation will be selected for the comparison with the predetermined fault criteria.
  • the selection of the higher amplitude between the fault frequency amplitude obtained from the calculation and the comparative fault frequency amplitude provides a more accurate induction motor fault analysis due to an error compensation in a measuring apparatus and a data collection device.
  • the method for detecting an induction motor fault is developed to automatically and simultaneously detect and determine the faults in main components which greatly affects the motor operation, i.e., the detection of an induction motor fault caused by a rotor damage, e.g., a rotor or shaft breakage, an induction motor fault caused by a stator damage, e.g., a winding short circuit, and an induction motor fault caused by an air gap imbalance.
  • a rotor damage e.g., a rotor or shaft breakage
  • an induction motor fault caused by a stator damage e.g., a winding short circuit
  • an induction motor fault caused by an air gap imbalance i.e., the detection of an induction motor fault caused by a rotor damage, e.g., a rotor or shaft breakage
  • an induction motor fault caused by a stator damage e.g., a winding short circuit
  • an induction motor fault caused by an air gap imbalance i.e
  • the detection of the motor fault caused by the rotor damage, the motor fault caused by the air gap imbalance, and the motor fault caused by the stator damage can be performed as follows.
  • the induction motor fault is caused by the rotor damage
  • the predetermined frequency range is defined by determining the amplitude at the power supply frequency, defining a start point of the frequency range, which is the point where the amplitude slope is lower than specified values both on the left side and the right side of the power supply frequency, and defining an end point of the frequency range, which is the point where the frequency is 3 Hz away from the start point towards the side which is away from the power supply frequency.
  • R s is a number of rotor slot
  • the induction motor fault is caused by the air gap imbalance
  • R s is the number of rotor slot
  • the induction motor fault is caused by the stator damage
  • the predetermined frequency range is defined by using the fault frequency caused by the stator damage as a reference point and defining the frequency range towards the left side and the right side to be away from the reference point with a distance of 5% of power supply frequency.
  • the detection of the induction motor fault caused by the stator damage according to the present invention can further comprise determining whether a current unbalance is in an acceptable range prior to defining the predetermined frequency range.
  • An acceptable current unbalance can be adjusted in accordance with certain application. For example, an acceptable current unbalance may be specified as does not exceed 5%.
  • converting the current signal data in the time domain into the current signal data in the frequency domain is performed using a fast Fourier transform (FFT) method.
  • FFT fast Fourier transform
  • the method of the present invention may further comprise demodulating the current signal data in the frequency domain to eliminate an electrical signal and determine a mechanical frequency signal.
  • the method for auto-detecting the induction motor fault according to the present invention may comprise predicting an induction motor’s remaining lifespan, which is performed by creating a trend line of the fault frequency amplitude, which is obtained by selecting the higher amplitude between the fault frequency amplitude obtained from the calculation and the comparative fault frequency amplitude, and determining the induction motor’s remaining lifespan using a regression analysis method to analyze the trend line of the fault frequency amplitude, which is obtained by selecting the higher amplitude between the fault frequency amplitude obtained from the calculation and the comparative fault frequency amplitude.
  • the determination of the induction motor’s remaining lifespan enables the operator to plan a maintenance or a replacement of components more effectively.
  • the operator is able to plan when to deactivate machines used in a manufacturing process for a motor maintenance in due time and allocate a budget to purchase spare parts of the motor components in advance.
  • Another aspect of the present invention relates to the system for auto-detecting the induction motor fault.
  • the system for detecting the induction motor fault comprises: the current measuring device for measuring the current supplying the induction motor to obtain the current signal data in the time domain, the processor provided for converting the current signal data in the time domain into the current signal data in the frequency domain, determining the fault frequency amplitude obtained from the calculation using the rotor speed at the rotor frequency where the amplitude is maximum in a range between the induction motor’s synchronous frequency and the induction motor’s full load driving frequency, determining the comparative fault frequency amplitude by determining the highest amplitude in the predetermined frequency range, and analyzing the induction motor fault by performing according to the following conditions: in a case where the highest comparative fault frequency amplitude is in the predetermined frequency range, the higher amplitude between the fault frequency amplitude obtained from the calculation and the comparative fault frequency amplitude is selected for the comparison with the predetermined fault criteria, or in a case where the highest comparative fault frequency amplitude is outside the predetermined frequency range, the fault
  • the determination of the fault frequency amplitude by the calculation and the predetermined frequency range for detecting the induction motor fault caused by the rotor damage, air gap imbalance and stator damage, the conversion of the current signal data in the time domain into the current signal data in the frequency domain, and the demodulation performed in the processor of the detection system according to the present invention can be performed as described in the description of the invention regarding the method for detecting the induction motor fault.
  • the system for auto -detecting the induction motor fault according to the present invention further comprises an additional processor provided for predicting the induction motor’s remaining lifespan, wherein the prediction of the induction motor’s remaining lifespan can be performed according to the method previously described.
  • the processor and the additional processor may be provided in a physical server or a virtual server.
  • the processor and the additional processor may be provided in a cloud server.
  • the display device which can be used is a computer, laptop, mobile phone, tablet, etc.
  • the display device preferably displays data comprising induction motor fault status, induction motor’s remaining lifespan, current unbalance, fault frequency amplitude trend line, rotor speed trend line, and current.
  • the display device may display data other than those mentioned above.
  • the display device displaying the data can communicate with the processor in real time so that when a fault occurs, the system can notify the user immediately.
  • the accuracy and reliability of the induction motor fault detection are tested using the method and system according to the present invention in comparison with the induction motor fault detection using conventional apparatuses and methods.
  • the detection of an on-load induction motor fault was performed using the method and system of the present invention by using a current transformer as a device for measuring the current supplied to the motor, processing the obtained current data in the processor, and displaying the motor faults, which are categorized into a fault caused by the stator winding short circuit, a fault caused by the rotor damage, and a fault caused by the air gap imbalance.
  • the detection of an on-load induction motor fault was performed by using a tachometer to measure the motor rotational speed in RPM, calculating the obtained data as a frequency composition data, and analyzing for an amplitude indicating a fault in the motor components.
  • test results in Table 1 show that by using the online method and system according to the present invention to detect the motor fault, the amplitude which exceeds the specified fault criteria was detected and the detection status was shown to detect a fault in the motor’s rotor.
  • test results in Table 2 show that by using the online method and system according to the present invention to detect the motor fault, the lower and upper side amplitudes exceeding the specified fault criteria were detected and the detection status was shown to detect a fault caused by the air gap imbalance.
  • test results in Table 3 show that by using the automated method and system according to the present invention to detect the motor fault, all lower sideband amplitudes and some upper sideband amplitudes exceeding the specified fault criteria were detected and the detection status was shown to detect a fault caused by the stator winding short circuit, although the short circuit percentage is not very high (for example, at 10% and 20%).
  • the determination of the comparative fault frequency amplitude may be performed prior to the determination of the fault frequency amplitude by the calculation or may be performed simultaneously with the determination of the fault frequency amplitude by the calculation. Any modifications and changes evident to a person of ordinary skill in the art should be considered to be within the spirit, scope, and concept of the present invention.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Tests Of Circuit Breakers, Generators, And Electric Motors (AREA)
  • Control Of Ac Motors In General (AREA)

Abstract

La présente invention se rapporte à un procédé d'auto-détection d'un défaut de moteur à induction consistant à mesurer le courant fourni au moteur à induction afin d'obtenir des données de signal de courant dans un domaine temporel, à convertir les données de signal de courant dans le domaine temporel en données de signal de courant dans un domaine fréquentiel, à déterminer une amplitude de fréquence de défaut à partir d'un calcul à l'aide d'une vitesse de rotor à une fréquence de rotor où l'amplitude est maximale dans une plage entre la fréquence synchrone du moteur à induction et la fréquence d'attaque de pleine charge du moteur à induction, à déterminer une amplitude de fréquence de défaut comparative par la détermination de l'amplitude la plus élevée dans une plage de fréquences prédéterminée, et à analyser le défaut de moteur à induction par une exécution conforme aux conditions spécifiées selon la présente invention. Le procédé peut consister en outre à prédire une durée de vie restante de moteur à induction.
PCT/IB2021/060842 2020-11-23 2021-11-23 Procédé et système d'auto-détection de défaut de moteur à induction WO2022107100A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TH2001006682 2020-11-23
TH2001006682 2020-11-23

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WO2022107100A1 true WO2022107100A1 (fr) 2022-05-27

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20110111829A (ko) * 2010-04-05 2011-10-12 한국전기연구원 전동기의 온-사이트 결함 진단 방법
US20150260794A1 (en) * 2014-03-11 2015-09-17 Rolls-Royce Plc Fault detection in induction machines
WO2019167086A1 (fr) * 2018-03-01 2019-09-06 Aurobinda Routray Système d'évaluation de multiples défauts dans des moteurs à induction

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20110111829A (ko) * 2010-04-05 2011-10-12 한국전기연구원 전동기의 온-사이트 결함 진단 방법
US20150260794A1 (en) * 2014-03-11 2015-09-17 Rolls-Royce Plc Fault detection in induction machines
WO2019167086A1 (fr) * 2018-03-01 2019-09-06 Aurobinda Routray Système d'évaluation de multiples défauts dans des moteurs à induction

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
MILJKOVIĆ DUBRAVKO: "Brief Review of Motor Current Signature Analysis", CRSNDT JOURNAL, vol. 5, no. 1, 1 January 2015 (2015-01-01), pages 15 - 26, XP055939830 *

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