Static Rotor Eccentricity Research Articles

Investigation of electromagnetic processes in the case of static eccentricity of a two-pole induction motor with a short-circuited rotor

Purpose. Correction of the mathematical model of electromagnetic processes in a two-pole induction motor with a short-circuited rotor, taking into account static rotor eccentricity to identify diagnostic correlations. Methodology. Analytical modeling using the method of specific magnetic conductivity, mathematical modeling of electromagnetic fields in a three-phase induction motor with a short-circuited rotor using methods of electromagnetic field theory and finite element methods. Obtained results. The necessity of improving mathematical models for induction motors with short-circuited rotors to establish new or refine connections between diagnostic features and diagnosed defects has been demonstrated. Refined mathematical expressions for calculating the specific conductivity of non-uniform air gaps in induction motors with static eccentricity are provided. Modeling was performed using the FEMM environment for a statically eccentric two-pole induction motor with a short-circuited rotor. It has been proven that the harmonic order values obtained using the numerical-field method are consistent with those obtained analytically. Findings. Based on the field approach and using the finite elements method, an analysis of the distribution of magnetic field in a two-pole induction motor with a short-circuited rotor was conducted. Harmonic analysis of the magnetic field in the air gap was performed to identify the fundamental harmonic and higher and lower-order harmonics when eccentricity occurs. The influence of static rotor eccentricity on the electromagnetic processes of the induction motor was analyzed. Practical value. The results of the study can be utilized for functional diagnosis of the rotor winding of induction motors based on the radial component of the magnetic field. This will contribute to enhancing the reliability of induction motors and enable the prevention of failure in induction motors with short-circuited rotors.

Dynamic characteristics analysis of asynchronous motorized spindle considering combined unbalanced magnetic pull and nonlinear bearing restoring force effects

The built-in motor of the motorized spindle is the key to realizing its movement. However, the unbalanced magnetic pull (UMP) generated in the built-in motor seriously affects its dynamic stability. In this work, a generalized time-varying dynamic model of the motorized spindle is proposed to evaluate the effect of dynamic loads on the spindle system. The external dynamic loads on the spindle mainly include the UMP generated by the built-in motor, the nonlinear restoring force of the bearing, and the eccentric excitation of the system mass. Considering the change of magnetic path caused by the dynamic displacement of the rotor, the radial and axial projection model and additional torque model of UMP are proposed. Numerical simulations are employed to handle the dynamical equation containing the time-varying UMP function. Based on the simulation results, the effects of built-in motor parameters, bearing parameters, rotor static eccentricity, and other factors on the dynamic characteristics of the spindle system are analyzed. The numerical results of the vibrations are verified experimentally.

Influence of Rotor Eccentricity On Electromagnetic Performance of 2-pole/3-slot PM Motors

This paper investigates the influence of static and dynamic rotor eccentricities on electromagnetic performance, including air-gap flux density, back electromotive force (EMF), electromagnetic torque, cogging torque, and unbalanced magnetic force (UMF), of a 2-pole/3-slot permanent magnet (PM) motor considering eccentricity ratio, eccentricity angle, and rotor initial angle. Both finite element analyses and experiments show that in a 2-pole/3-slot PM motor, the static rotor eccentricity leads to unbalanced magnitudes and phase angles of fundamental back-EMFs of three phases but does not change the harmonic contents, while the dynamic rotor eccentricity will not cause unbalance in three phase back-EMFs but affects the harmonic contents of back-EMFs and their phase angles, which causes asymmetric positive and negative half-periods and corresponding even harmonics of phase back-EMF waveform. In addition, both static and dynamic rotor eccentricities have negligible influence on the average torque, but result in large torque ripple, cogging torque, and UMF.

Torque ripple reduction of brushless DC motor with convex arc‐type permanent magnets based on robust optimization design

The mass production of the motors causes tolerance of shape and dimension, deviation of permanent magnet remanence and rotor eccentricity error, which affect the cogging torque and torque ripple amplitude and performance consistency. In order to reduce the torque ripple of the motor in the actual condition, the robustness optimization is performed in the paper. Firstly, an improving convex arc type permanent magnet structure is adopted to improve air gap flux density and suppress the cogging torque. Secondly, the structure parameters of the magnetic pole are selected as optimization variables, and the magnetization angle, remanence and position of the permanent magnet, static and dynamic rotor eccentricity are considered as noise factors. To improve the overall robustness of the motor under different operating conditions, the dynamic Taguchi method is used to optimize the robustness of the motor, and the test data is processed through the relation analysis method to obtain the optimal combination of control factors. Finally, the prototype is manufactured for the experiment. Compared with the single-operating conditions robust optimization results, the robust optimization method improves the robustness of the motor. The cogging torque amplitude is reduced by 39.2%. The torque ripple is 38.4% lower than that before optimization.

A novel model-based metaheuristic method for prognostics of aerospace electromechanical actuators equipped with PMSM

The prior knowledge of incipient failures of primary flight command electromechanical actuators (EMAs) with prognostic algorithms can be very beneficial. Indeed, early and proper detection and interpretation of the deterioration pattern can warn for replacing the servomechanism before the actual manifestation of the abnormal behaviour. Furthermore, such algorithms often exploit a model-based approach established on the direct comparison between the actual (High Fidelity) and the monitor (Low Fidelity) systems to identify fault parameters through optimization processes. The monitor model allows the acquisition of accurate and precise results with a contained computational effort. The authors developed a new simplified monitor model capable of faithfully reproducing the dynamic response of a typical aerospace EMA equipped with a Permanent Magnet Sinusoidal Motor (PMSM). This digital twin senses mechanical and electrical faults: friction, backlash, coil short circuit, static rotor eccentricity, and proportional gain. Fault detection and identification task are performed by comparing the output signal of the reference system (real or simulated) with the one obtained from the monitor model. After that, the Genetic Algorithm is chosen as the optimization algorithm to match the two signals by iteratively changing the fault parameters to detect the global minimum of a quadratic error function. Once a suitable fit is obtained, the corresponding optimization parameters are correlated with the considered progressive failures to evaluate the system’s health status. The high-fidelity reference models analysed in this work have been previously conceived, developed, implemented in Matlab-Simulink, and validated experimentally by researchers of the ASTRA group of the DIMEAS of Politecnico di Torino.

Closed-Loop Drive Detection and Diagnosis of Multiple Combined Faults in Induction Motor Through Model-Based and Neuro-Fuzzy Network Techniques

In this paper, a fault detection and diagnosis approach adopted for an input-output feedback linearization (IOFL) control of induction motor (IM) drive is proposed. This approach has been employed to detect and identify the simple and mixed broken rotor bars and static air-gap eccentricity faults right from the start its operation by utilizing advanced techniques. Therefore, two techniques are applied: the model-based strategy, which is an online method used to generate residual stator current signal in order to indicate the presence of possible failures by means of the sliding mode observer (SMO) in the closed-loop drive. However, this strategy is not able to recognise the fault types and it can be affected by the other disturbances. Therefore, the offline method using the multi-adaptive neuro-fuzzy inference system (MANAFIS) technique is proposed to identify the faults and distinguish them. However, the MANAFIS required a relevant database to achieve satisfactory results. Hence, the stator current analysis based on the HFFT combination of the Hilbert transform (HT) and Fast Fourier transform (FFT) is applied to extract the amplitude of harmonics due to defects occur and used them as an input data set for the MANFIS under different loads and fault severities. The simulation results show the efficiency of the proposed techniques and its ability to detect and diagnose any minor faults in a closed-loop drive of IM.

Research of dampher system damage physical processes of synchronous machines rotor

The physical processes in the damper system of the rotor with the appearance of a static eccentricity of the rotor for two types of salient-pole synchronous machines - a capsule hydrogenator SGK 538/160-70M with a capacity of 22 MW and a synchronous generator with a capacity of 500 kW were investigated by means of mathematical modeling. A field mathematical model has been developed that takes into account the combined action of three physical fields of different nature: electromagnetic, temperature and field of thermomechanical stresses, and makes it possible to evaluate the heating and three-dimensional distribution of thermomechanical stresses in the structural elements of the rotor damper system of a salient-pole synchronous machine. These physical processes cause gradual destruction of the structure of the rotor damper system. It is proved that the primary cause of degradation and damage of the damping system of the rotor of an open-pole synchronous machine is the uneven distribution of induced currents in the rods at the poles of the rotor, which occurs when the machine works asynchronously or with the appearance of rotor static eccentricity. The largest induced currents and heat occur in the rods located at the edges of the pole pieces, while the central rods at the pole are heated significantly less. This asymmetric heating of the damping system of the rotor leads to significant thermomechanical stresses in the elements of the damping system of the rotor, which significantly depend on the magnitude of the eccentricity and slippery of the rotor in asynchronous mode. The magnitude of the total thermomechanical stresses in the rods is influenced not only by axially directed forces but also by transverse forces in the end short-circuiting elements. At considerable slippery and eccentricities there are inadmissibly big breaking forces which break cores and face short-circuiting elements of a damping system of a rotor. According to the results of the analysis, the heating and thermomechanical stresses of the structural elements were determined and recommendations for its structural improvement were given.

Effect of Static Rotor Eccentricity on End Winding Forces and Vibration Wearing

In order to study the vibration wearing regularity and the strength failure point of stator end windings before and after static rotor eccentricity, the three-dimensional electromagnetic forces and the subsequent mechanical responses are studied in this paper. The electromagnetic force, stress, and deformation on the end winding of the QFSN-600-2YHG turbo-generator are calculated by the finite element method (FEM) through an electromagnetic-structure coupling. The radial vibration characteristics of the winding are verified by experiments. It shows that the vibration wearing in the same layer is more serious than that between two neighboring layers. For different layers, the interphase coils endure a larger wearing risk than the innerphase coils. Inside the same phase, the last coil along the rotating direction has the highest risk of insulation wearing. The occurrence of static rotor eccentricity will significantly increase the electromagnetic forces and the vibration amplitudes on some coils. The end-phase coil which is close to the minimum air-gap point is the most dangerous one due to the lasting overstresses and the intensified deformations.

Diagnostics of Electro-Mechanical Actuators Based Upon the Back-EMF Reconstruction

Electrical systems are gradually replacing the more traditional hydraulic and pneumatic solutions for the transmission of secondary energy for onboard aircraft equipment. Therefore fault detection and health management strategies properly conceived for electrical devices are becoming a highly relevant topic for research and development in the aerospace disciplines. One possible practical implementation of these methodologies would be the identification of parameters for diagnostic and prognostic monitoring, which are highly sensitive to incipient faults but, at the same time, are less influenced by operating conditions (external loads, command input, temperatures, etc.). In this paper, the authors evaluated the effectiveness of counter-electromotive force (back-EMF) coefficient as a prognostic parameter, emphasizing a novel sampling approach that significantly lower the computational effort required while maintaining a good back-EMF coefficient curve reconstruction. The approach is virtual sensor-like, using only already available data for the correct operation of the BLDC motor. The proposed method was tested by evaluating the back-EMF coefficient reconstruction as a function of some progressive failures typical of EMA motors, such as inter-turn partial shorts and rotor static eccentricity. Its robustness to external disturbances has been tested by evaluating different actuation commands and operating conditions. As expected, the back-EMF signal shows a marked dependence on the considered failure modes and, at the same time, a suitable insensitivity to the other external factors.

STATIC ECCENTRICITY FAULT DETECTION METHOD FOR ELECTRICAL ROTATING MACHINES BASED ON THE MAGNETIC FIELD ANALYSIS IN THE AIR GAP BY MEASURING COILS

Electrical rotating machines have a great economic significance as they enable conversion of energy between mechanical and electrical state. Reliability and operation safety of these machines can be greatly improved by implementation of continuous condition monitoring and supervisory systems. Especially important feature of such systems is the ability of early fault detection. For this reason, several methods for detection and diagnosis of the machine faults have been developed and designed. As fault detection methods can largely differ in the types of detectable faults, machine adoptability and price of the system, a novel method was developed that can be used for cost-effective detection of various faults of electrical machine. Machine fault detection technique presented in this paper is based on the measurement of magnetic field in the air gap. Numerous studies have proven that crucial information about the machine condition can be determined based on measurement and analysis of the magnetic field in the air gap. It has also been confirmed that analysis of the air gap magnetic field can be used to detect, diagnose and recognize various electrical faults in their very early stage. Proposed method of positioning and installation of the measuring coils on ferromagnetic core parts within the air gap region of the machine enables differentiation of various faults. Furthermore, different faults can be detected if measuring coils are placed on the stator teeth then when placed on the rotor side. The paper presents method on how to analyse and process the measured voltages acquired from measuring coils placed within the machine, especially in the case of rotor static eccentricity detection. The methodology is explained by means of finite element method (FEM) calculations and verified by measurements that were performed on the induction machine. FEM calculation model was used to predict measurement coil output of the induction motor for healthy and various faulty states (at different amounts of static eccentricity). These results were then confirmed by measurements performed in the laboratory on the induction traction motor that was specially modified to enable measurements of faulty operation states of the machine. Measurements comprised of several machine fault conditions broken one rotor bar, broken multiple rotor bars, broken rotor end ring and various levels of rotor static eccentricity.
 Other methods used for faults detection are primarily based on the monitoring of quantities such as current and vibration and their harmonic analysis. This new system is based on the tracing the changes of induced voltage of the measuring coils installed on the stator teeth. Faults can be detected and differentiated based on RMS value of these voltages and the number of voltage spikes of voltage waveform i.e. without the need of harmonic analyses. If these coils are installed on the rotor it is possible to detect the stator winding faults in a similar manner.

Electromagnetic Characteristic Analysis of Permanent Magnet Synchronous Machine Considering Current Waveform According to Static Rotor Eccentricity

In this study, we performed an electromagnetic characteristic analysis of a permanent magnet synchronous machine considering the current waveform based on static rotor eccentricity. First, the characteristics of the back electromotive force were analyzed through the no-load analysis of the analysis model according to static rotor eccentricity. Next, a dynamic analysis was performed through mathematical modeling of a permanent magnet synchronous motor and PWM method. The input current during operation was derived through the dynamic analysis, and the core loss analysis was performed using derived input current. The core loss analysis was performed using the case where the fundamental wave current was applied and the input current derived through the dynamic analysis, and the results were compared.

Evaluation of the Correlation Coefficient as a Prognostic Indicator for Electromechanical Servomechanism Failures

In order to identify incipient failures due to a progressive wear of a primary flight command electromechanical actuator, several approaches could be employed; the choice of the best ones is driven by the efficacy shown in fault detection/identification, since not all the algorithms might be useful for the proposed purpose. In other words, some of them could be suitable only for certain applications while they could not give useful results for others. Developing a fault detection algorithm able to identify the precursors of the abovementioned electromechanical actuator (EMA) failure and its degradation pattern is thus beneficial for anticipating the incoming malfunction and alerting the maintenance crew such to properly schedule the servomechanism replacement. The research presented in the paper was focused to develop a fault detection/identification technique, able to identify symptoms alerting that an EMA component is degrading and will eventually exhibit an anomalous behavior, and to evaluate its potential use as prognostic indicator for the considered progressive faults (i.e. frictions and mechanical backlash acting on transmission, stator coil short circuit, rotor static eccentricity). To this purpose, an innovative model based fault detection technique has been developed merging several information achieved by means of Fast Fourier Transform (FFT) analysis and proper "failure precursors" (calculated by comparing the actual EMA responses with the expected ones). To assess the performance of the proposed technique, an appropriate simulation test environment was developed: the results showed an adequaterobustness and confidence was gained in the ability to early identify an eventual EMA malfunctioning with low risk of false alarms or missed failures.

Condition Monitoring of Motor-Gear System Dynamics With Rotor and Gear Faults

Abstract An electromechanical system consisting of an electric motor and planetary gear set is modeled and analyzed in this paper. The model integrates various internal excitations including time-varying gear mesh stiffness, nonlinear spatial effect and, saturation effect, and component flaws. The simulation results predict the effects of rotor and gear faults including broken rotor bar, rotor static and dynamic eccentricity, and tooth root crack of the gear on the electromechanical system behavior. It is verified as the results obtained are in accordance with the features derived within previous researches. Furthermore, new sidebands merged on the dynamic response spectra such as slip frequency harmonics, rotor rotational frequency harmonics, and fault-related rotational frequency harmonics can be applied to detect electrical and mechanical faults in the motor-gear system. This paper lays the foundation for the comprehensive further study of working condition monitoring for the motor-gear system.

Analytical modelling of radial suspension force in bearingless surface‐mounted PM synchronous motors considering static rotor eccentricity

In this study, a new analytical model is provided in order to calculate the radial suspension force in bearingless surface-mounted permanent magnet synchronous motor with static rotor eccentricity. The proposed model is based on the harmonic analysis of magnetic flux density, and considers the influence of both radial and tangential air-gap field components on the computation of radial suspension force. This model can reveal the generation mechanism of the radial suspension force and identify the generation sources of the force ripples. Furthermore, the magnitudes and frequencies of radial suspension force harmonics, and the relationship between the radial suspension force and rotor eccentric displacements can be accurately predicted by the proposed model. However, this model cannot be used for saturated machines. The analytical model is verified by finite-element analyses and the result of static experimental study.

Effect of 3D Unidirectional and Hybrid SAGE on Electromagnetic Torque Fluctuation Characteristics in Synchronous Generator

This paper presents a comprehensive study on the variation laws of electromagnetic torque (EMT) under static air-gap eccentricity (SAGE) conditions in synchronous generators. Different from other studies, this paper focuses on not only the impact of radial SAGE, but also the effect of axial and hybrid SAGE, on the EMT fluctuation characteristics, i.e., we actually study the 3D static rotor eccentricity. The theoretical analysis model is first set up to study the influence of SAGE on the magnetomotive force (MFD) and EMT. Then, the finite element calculation and the experimental study on the CS-5 prototype generator which is of two poles and 3000 rpm are carried out to validate the theoretical analysis. It is shown that the radial SAGE will increase the dc component of MFD and shift the whole MFD curve and the phase current upwardly, while the axial SAGE will reduce the dc component as well as the amplitudes of both the MFD and the phase current like a compressing operation. In general, no matter in unidirectional or hybrid SAGE cases, the radial SAGE will intensify the EMT ripple and increase each harmonic of EMT, while axial SAGE will play the opposite role. The research conclusion obtained in this paper is potential to be applied as a supplement criterion for the condition monitoring and control of the eccentricity faults.

A novel negative dislocated seal and influential parameter analyses of static/rotordynamic characteristics

This paper proposes a new type of negative dislocated seal (NDS) based on the dislocated bearing theory to investigate the influential parameters of static rotor eccentricity and dislocated ratio on the static and rotordynamic characteristics of an example seal solved with computational fluid dynamics (CFD) the flow field. The rotordynamic characteristics of the NDS were investigated in respect of the effects of rotor whirling frequency on response force, stiffness coefficients, damping coefficients and rotor system stability, by multifrequency elliptical orbit rotor whirling model. Based on the studies, we reached the following conclusions. The circumferential pressure distribution of NDS and conventional labyrinth seal (LS) presents sine periodic variation approximately, while relative to the LS, the NDS has two divergent wedge gaps and reduces the hydrodynamic pressure effects, then the circumferential pressure difference and tangential force on rotor surface decreases by about 40 %~190 %. The leakage of the NDS linearly increases with the rising eccentricity ratio and dislocation ratio approximately, and is larger (about 0.9 %~1.5 %) than the LS. The direct stiffness coefficients of the two seals increase with the rise of rotor whirling frequency, while the absolute values of both the cross-coupled stiffness coefficients and the damping coefficients decrease with raising rotor whirling frequency. Compared with the LS, the NDS has smaller (about 28.8 %~206.2 %) cross-coupled stiffness coefficient, larger (about 26.15 %~60.39 %) effective damping coefficient, and good stability of rotor system. This study has developed a novel seal structure to improve the seal performance of turbomachinery such as aeroengine.

Prognostics of Onboard Electromechanical Actuators: a New Approach Based on Spectral Analysis Techniques

In the last years, the layout of servomechanisms used in the aeronautical field to actuate the flight controls has changed radically and, nowadays electromechanical actuators (EMAs) are increasingly replacing the older hydraulic powered actuator types. The definition of special monitoring procedures, based on the analysis of the system response and aiming to evaluate the evolution of faults, represents an important task of the modern system engineering taking into account that onboard actuators are typically safety critical items. The present paper proposes a new prognostic procedure centered on the characterization of the state of health of an EMA used in aircraft primary flight controls. This approach, based on the innovative use of a model-based fault detection and identification method (FDI), identifies the actuator actual state of wear of the actuator analyzing proper system operational parameters, able to put in evidence the corresponding degradation path, by means of a numerical algorithm based on spectral analysis techniques. The proposed FDI algorithm has been tested in case of EMA affected by two progressive failures (rotor static eccentricity and stator phase turn-to-turn short-circuit), showing an adequate robustness and a suitable ability to early identify EMA malfunctions with low risk of false alarms or missed failures.

New prognostic neural method by discrete wavelet transforms for electromechanical flight controls affected by progressive faults

Progressive failures affecting onboard electromechanical actuators (EMA), especially if related to primary flight commands, could be a critical issue for the aircraft reliability and, in the worst cases, could compromise its safety. In the last years strong interest is expected by the development of prognostic algorithms able to provide an early identification of the precursors of EMA progressive failures. In this work authors proposes a new prognostic method based on two artificial neural networks (ANN), a basic and an enhanced feedforward neural network, performing the fault detection and identification of two critical progressive faults often affecting the EMA brushless motor (i.e. turn-to-turn short circuit of a stator coil and rotor static eccentricity); in order to identify a suitable data set able to guarantee an affordable ANN classification, the said failures precursors are properly pre-processed by a Discrete Wavelet Transform, extracting several features used as input of the proposed prognostic algorithm.

Rotordynamic Computational and Experimental Characterization of a Convergent Honeycomb Seal Tested With Negative Preswirl, High Pressure With Static Eccentricity and Angular Misalignment

Hole-pattern or honeycomb seals have been commonly used for many years in the Oil & Gas industry as damper seals for turbomachinery. The main motivation has been to introduce additional damping to improve the shaft rotordynamic stability operating under high-pressure conditions. Experience has shown that the dynamic and even static characteristics of those seals are very sensitive to the operating clearance profile as well as the installation tolerances. Rotordynamic stability is related not only to the seal effective damping but to the effective stiffness as well. In fact, for this kind of seal, the effective stiffness can be high enough to alter the rotor system's natural frequency. The seal stiffness is strictly related to the tapering contour: if the clearance profile changes from divergent to convergent, the effective stiffness may change from a strong negative to a strong positive magnitude, thus avoiding the rotor natural frequency drop as it is detrimental for the stability. Unfortunately, the effective damping is reduced at the same time but this effect can be mitigated using proper devices to keep the preswirl low or even negative (e.g., swirl brakes and shunt holes). This paper presents the results from an extended test campaign performed in a high-speed rotor test rig equipped with active magnetic bearings (AMBs) working under high pressure (14 krpm, 200 bar gas inlet pressure), with the aim to validate the rotordynamic characteristics of a negative preswirl, convergent honeycomb seal and demonstrate its ability to effectively act as a gas bearing as well as a seal. The test plan included variations of inlet pressure, differential pressure (given the same inlet pressure), as well as rotational speed in order to fully validate the seal behavior. This kind of test was performed in a “dynamic mode” that is to say exciting the spinning test rotor through a pair of AMBs along linear orbits. Additionally, the impact of the seal to rotor static eccentricity and the seal to rotor angular misalignment were both experimentally investigated and compared to relevant computational fluid dynamics (CFD) simulations. This kind of test was performed in a “static mode,” that is to say imposing through the AMBs the required eccentricity/angular misalignment and then measuring the forces needed to keep the rotor in the original position. Dynamic mode test was also performed in order to check the impact of the seal static eccentricity on its dynamic behavior. Finally, the test results were compared with predictions from a state of the art bulk-flow code in order to check the predictability level for future design applications.

Analysis of magnetic field and levitation force characteristics for 3-DOF deflection type PM motors

The mechanism and characteristics of the electromagnetic radial force are important for motors with complicated structures. The three-dimensional analytical model of the air gap between the rotor and stator is established under rotor eccentricity conditions. Then, aiming at solving the unbalanced radial force problem with rotor static eccentricity, the air-gap flux density, radial electromagnetic force, and the comparisons of harmonic contents are calculated and presented based on FEA (Finite Element Analysis) and MATLAB simulation. Finally, the magnetic field model has been validated by experiments utilizing a prototype system. The results provide a theoretical guide for configuration design, optimization, and levitation control research on three degree of freedom deflection type motors.