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Condition Monitoring and Fault Diagnosis of Induction Motors using Vibration Signal
Applications
Induction Motors
Fault diagnosis
Allows the machine operator to have the necessary spare parts before the machine is stripped down, thereby reducing outage times Can be integrated into the maintenance policy, therefore the usual maintenance at specified intervals can be replaced by a condition-based maintenance
Failure survey in induction motors Components Bearing Stator Rotor Others Failure 40% 38% 10% 12%
Method
Vibration MCSA Axial flux Lubricating oil debris Cooling gaps Partial discharge
No No No No Yes Yes
Very popular, easy and accurate Favored by mechanical engineers Exists a lot of skilled and experience Often a direct link with the problem Piezo-electric vibration transducers are most popular Axial, radial, and tangential where radial is used for mechanical problems and tangential is used for detecting electrical problems
Vibration Signature
Data acquisition
Machinery (Motor)
Pre-processing
Wavelet transform
Feature extraction
Feature algorithm
Fault diagnosis
ART-KNN
Full load
Over load
Bearing
Motor
Common bed
Sensors positions
Control Panel
Speedometer (Channel 4) (Channel 4) Channel 1-3: current signal Channel 4: run speed Channel 5-8: vibration signal AC current probes (Channel 1-3)
Measuring instruments
B & K Condition Amplifier
Mechanical problems
Fault Unbalance Misalignment & bent shaft Damaged rolling element bearing (ball, races, etc.) Damaged and worn gears Mechanical looseness Rotor rub Dominant Vibration Frequency 1x rpm ( temperature & lad dependent) 1x rpm usually, 2x rpm often, 3x & 4x rpm sometimes Impact rates for the individual bearing components. Also vibrations at very high frequencies. Tooth meshing frequencies (shaft rpm teeth number) and harmonics 2x rpm 0.5x, 1.5x, 2.5x, 3.5x, etc. 0.5x, 1x, 1.5x, 2x, etc.
Oil whirl & whip in sleeve bearings 0.43-0.48x rpm pressure fed bearings only
Electrical problems
Fault Unbalanced supply inputs Stator asymmetry (unbalanced supply, inter turn short) Rotor asymmetry (broken rotor bar, broken end ring) Eccentricity (static/dynamic) Adjustable speed drives Dominant Vibration Frequency 1x supply frequency Double supply frequency Double slip frequency 1x-slip frequency Double supply Double slip frequency 6x supply and harmonics
NSK
6203
0.3125
1.319
3X 178.59 Hz 172.95 Hz
0.3835
3.066
4.932
2.03
Amplitude
0.02 0.00 -0.02 -0.04 -0.06 -0.08 -0.10 0.00 0.01 0.02 0.03 0.04 0.05 0.06
Amplitude
0.02 0.00 -0.02 -0.04 -0.06 -0.08 -0.10 0.00 0.01 0.02 0.03 0.04 0.05 0.06
Time (s)
Time (s)
No-load condition
Full-load condition
fo
0.015 Amplitude
0.015
0.010
Amplitude
0.010
1x
0.005
0.005
2x 1x
3x
2x
3x
fo
0.000
20
40
60
No-load condition
Full-load condition
Wavelet transform
No-load condition
Full-load condition
Main reasons for the rotor bar and end ring breakage are: Thermal stress due to thermal overload and unbalance, hot-spots, sparking or excessive losses Magnetic stress caused by electromagnetic forces, unbalance magnetic pull electromagnetic noise and vibration Residual stresses due to manufacturing problems Dynamic stresses arising from shaft torque, centrifugal forces and cyclic stress Environment stresses caused by contamination or abrasion of the rotor materials due to chemical or moisture Mechanical stress due to loose laminations, fatigued parts or bearing failure
0.0010
0.0008
0.0008
Amplitude
3 f 3sf
0.0006
Amplitude
0.0006
0.0004
3 f 10 sf 2x 1x 2f - sf 2f + sf
0.0004
1x f + sf 2x
3x
0.0002
0.0002
Frequency (Hz)
Frequency (Hz)
No-load condition
Full-load condition
3. Rotor unbalance
Experimental objective Mechanical unbalance effect to vibration signal Experimental conditions Adding unbalance mass at an end of end ring Unbalance condition
Mass : 8.4 g Distance: 40.2 mm Position: 0 , 36 , 72
Unbalance mass
Noraml Unbalance
0.0020 0.0018
Unbalance Noraml
1x
1x
Amplitude
Amplitude
53
54
55
56
57
58
59
60
61
62
63
Time (s)
Time (s)
No-load condition
Full-load condition
Experimental conditions
Air-gap: 0.25 mm Deflection in mid-span: 0.075 mm
0.010
1x
0.008
0.008
Amplitude
Amplitude
0.006
0.006
0.004
0.004
2x
1x
0.002
2x
0.002
Frequency (Hz)
Frequency (Hz)
No-load condition
Full-load condition
Geometrical center
Angular misalignment
Characteristic frequency components: double supply frequency, slip frequency No-load condition
Normal condition
Parallel eccentricity
Angular eccentricity
Full-load condition
Normal condition
Parallel eccentricity
Angle eccentricity
Feature extraction
Feature parameters: Mean, RMS, Shape factor, Skewness, Kurtosis, Crest factor
RMSF, FC, RVF, Entropy Estimations, Entropy error, Histogram (upper-bound and lower-bound)
Full-load condition
160 140
100
No-load Full-load
No-load Full-load
95
Number of neurons
120 100 80 60 40 20 0 0.800 0.825 0.850 0.875 0.900 0.925 0.950 0.975 1.000
90
85
80
75
70
65 0.800
0.825
0.850
0.875
0.900
0.925
0.950
0.975
1.000
Similarity coefficient
Similarity coefficient
Summary
Various motor conditions are tested under no-load, full-load conditions Faulty bearing (outer race) Rotor bar broken Rotor unbalance Bowed rotor shaft Rotor misalignment (parallel and angular)
The vibration analysis for motor faults is efficient tool The features of signals can be extracted through vibration signatures Classification algorithm, ART-KNN, are carried out to learn and classify the conditions. The results can reach 100% success rate.
Time Schedule
Content Month 1 2 3 4 5 6 7 8 9 10 11 12 Diagnosis system Efficiency Faulty bearing Rotor Eccentricity Faulty stator Feature extraction Feature selection Diagnosis system test Dealing with problem Unbalance Rotor, Bowed Rotor Experiments Signal acquisition and Feature extraction Vibration signal and stator current signal Data diagnosis (vibration & current) Diagnosis (ART-KNN) Others
. .
Sensing
. .
Data Fusion
Reasoning