Abstract
A non-invasive technique for condition monitoring of brushless DC motor drives is proposed in this study for Hall-effect position sensor fault diagnosis. Position sensor faults affect rotor position feedback, resulting in faulty transitions, which in turn cause current fluctuations and mechanical oscillations, derating system performance and threatening life expectancy. The main concept of the proposed technique is to detect the faults using vibration signals, acquired by low-cost piezoelectric sensors. With this aim, the frequency spectrum of the piezoelectric sensor output signal is analyzed both under the healthy and faulty operating conditions to highlight the fault signature. Therefore, the second harmonic component of the vibration signal spectrum is evaluated as a reliable signature for the detection of misalignment faults, while the fourth harmonic component is investigated for the position sensor breakdown fault, considering both single and double sensor faults. As the fault signature is localized at these harmonic components, the Goertzel algorithm is promoted as an efficient tool for the harmonic analysis in a narrow frequency band. Simulation results of the system operation, under healthy and faulty conditions, are presented along with the experimental results, verifying the proposed technique performance in detecting the position sensor faults in a non-invasive manner.
Highlights
IntroductionPublisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations
The method is based on the analysis of motor vibration signals and the use of piezoelectric sensors is proposed as a low-cost implementation for the diagnosis or as a part of a smart sensor with the ability to analyze the acquired data, provide a fault alarm, and initiate an emergency system stop
The Hall-effect position sensor misalignment and breakdown faults are investigated, extending the previous study, where the piezoelectric sensors have been used for the diagnosis of the position sensor misalignment fault only
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. Energies 2021, 14, 2248 of detecting all the potential Hall-effect position sensor fault types, i.e., misalignment and single or double breakdown fault, without the need for hardware modification of the motor controller or additional external voltage or current sensors. In this way, a more generalized approach, independent of the drive system voltage and current ratings, can be achieved, as there is no need for doubling the required, application-based, current and voltage sensors. The experimental investigation of the system operation under the healthy and faulty conditions highlights the advantages of the piezoelectric transducers in detecting the faulty system operation
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