EXPERT MOTOR CONDITION MONITORING (EMCM)
procedures
Database
Signal conditioning
Data display, current
state, trends, alarms,
recommendation
Sensors
processed data
Client application Programs and other
systems
readings
Development engineers, programmers ...
Processing and working
unit
Execution
Norms, recommendations,
start phase
Traditional monitoring concept
Expert
Know-how transmission
Working
memory
Signal conditioning
Data display,
current state,
trends, alarms,
recommendation
Sensors learning
processed data
knowledge
Inference
module
Rules, procedures…
Client application
New
knowledge
Programs and other
systems, databases
readings
Development engineers, programmers ...
Knowledge
database
Processing and working
unit
Execution
Norms, recommendations,
start phase
FEM calculations and measurements
Expert monitoring concept
Information value from monitoring
Expert system provides additional value for users when it comes to predictive maintenance of the capital equipment.
inter-turn short circuit in the armature winding
presence of static eccentricity
termination of two rods of the cage rotor
bearing damage
Measured parameter has changed
“something is wrong” - Alarm
FEM calculations.
Calculation results.
Confirmation of calculations with experiments and industry applications.
NEW FAULT DETECTION METHODS (DMFM)
Analysis of calculated wave forms for correct and faulty machine conditions.
1
2
3
4
EMCM (EXPERT KNOWLEDGE IMPLEMENTED IN EMCM SYSTEM)
FEM Model
Finite Element Model (FEM) has been created to verify new algorithms in different loading conditions. Based on this model and real-world measurements, it has been demonstrated that accurate detection of shorted turns can be obtained without the need to vary the load on the machine if suitable sensors and algorithms are applied.
Expert knowledge for fault detection
Stator fault detection
1
Rotor fault detection
2
Differential measurement of the machine magnetic field enables fault detection
DMFM (Diferential Magnetic Field Measurement)
Patentted method for rotor broken bar detection or intercoil short circuit detection in rotor winding, based on diferential measurement of magnetic field using two measuring coils.
MEASURING VALUE (voltage) FAULT
voltage 0 V → no fault
voltage > 0 V → fault present
Detection of stator failure
Inter-coil short circuit current
Voltage of two serial connected coils
failure
No failure
failure
Detection of stator failure
Measurement coil 1
Measurement coil 2
Measurement coil for charging
Electronic circuit for failure detection
Applicable to induction machines with measurement coils
Rotor Failure Detection
Measurement coil 1
Measurement coil 2
Applicable to all types of induction machines
2
1
1
2 3
4
EMCM ( SYSTEM CONCEPT – FRONT END )
vibration
temperature
current
mag. field
1
2
3
4
Analog signals
EMCM ( SYSTEM CONCEPT )
EMCM
(standard communication)
Remote user
Ethernet
Sensors
EMCM detects: - one or more broken bars of the rotor cage - broken ring of the rotor cage - rotor eccentricity - bearing damage.
Local HMI
Remote web HMI
operator panel – HMI, web server – remote access,
database – data storage
Ethernet
measured data
system no. 1
USER
Ethernet
Ethernet
Ethernet
Ethernet
Firewall
EMCM ( INTEGRATION OF EMCM SYSTEMS – CONCEPT 1 )
system no. 2
system no. 3
measured
data
measured
data
USER