Method Of Identifying Fault In Synchronous Reluctance Electric Machine, Monitoring System And Synchronous Reluctance Electric Machine

Abstract

A method of identifying a fault in a synchronous reluctance electric machine, the method including carrying out a first vibration measurement on a stator in a first radial direction of the stator; carrying out a second vibration measurement on the stator in a second radial direction of the stator; determining, on the basis of at least one of the first vibration measurement and the second vibration measurement, a first vibration frequency; determining, on the basis of the first vibration measurement and the second vibration measurement, a mode shape of the vibration at the first vibration frequency; and determining, on the basis that the first vibration frequency f.sub.b and the mode shape m fulfil the following barrier fault conditions:

f.sub.b=f.sub.r, and m=1

where f.sub.r is a rotation frequency of a rotor, that a flux barrier of the rotor is defect.

Claims

1. A method of identifying a fault in a synchronous reluctance electric machine comprising a stator and a rotor, the rotor comprising a plurality of magnetically conductive core elements stacked in an axial direction of the rotor, and each core element includes flux barriers, the method comprising: carrying out a first vibration measurement on the stator in a first radial direction of the stator; carrying out a second vibration measurement on the stator in a second radial direction of the stator; determining, on the basis of at least one of the first vibration measurement and the second vibration measurement, a first vibration frequency; determining, on the basis of the first vibration measurement and the second vibration measurement, a mode shape of the vibration at the first vibration frequency; and determining, on the basis that the first vibration frequency f.sub.b and the mode shape m fulfil the following barrier fault conditions:
f.sub.b=f.sub.r, and m=1 where f.sub.r is a rotation frequency of the rotor, that a flux barrier of the rotor is defect.

2. The method according to claim 1, further comprising determining, on the basis that the first vibration frequency f.sub.b fulfils the following barrier fault condition: $f_b=\frac{f_s}{2p}$ where f.sub.s is a supply frequency and p is a number of stator pole pairs, that a flux barrier of the rotor is defect.

3. The method according to claim 1, wherein the method comprises: carrying out a plurality of vibration measurements in at least three different radial direction of the stator, such as at least four, at least six or at least eight different radial directions of the stator; determining, on the basis of at least one of the plurality of vibration measurements, a first vibration frequency; and determining, on the basis of the plurality of vibration measurements, a mode shape of the vibration at the first vibration frequency.

4. The method according to claim 1, further comprising determining that a flux barrier of the rotor is defect when the first vibration frequency and the mode shape fulfil the barrier fault conditions and when a vibration amplitude at the first vibration frequency exceeds a predetermined threshold value.

5. The method according to claim 1, wherein the determination whether the first vibration frequency and the mode shape fulfil the barrier fault conditions is performed continuously or repeatedly during operation of the synchronous reluctance electric machine.

6. The method according to claim 1, wherein the method is partly performed online.

7. A monitoring system for identifying a fault in a synchronous reluctance electric machine comprising a stator and a rotor, the rotor comprising a plurality of magnetically conductive core elements stacked in an axial direction of the rotor, and each core element includes flux barriers, the monitoring system comprising: a first sensor arranged to measure vibrations of the stator in a first radial direction of the stator; a second sensor arranged to measure vibrations of the stator in a second radial direction of the stator; and a control system comprising at least one data processing device and at least one memory having a computer program stored thereon, the computer program including a program code which, when executed by one or more of the at least one data processing device, causes one or more of the at least one data processing device to perform the steps of: detecting, based on measurement signals from the first sensor and the second sensor, a first vibration frequency and a mode shape of the vibration at the first vibration frequency; and determining, on the basis that the first vibration frequency f.sub.b and the mode shape m fulfil the following barrier fault conditions:
f.sub.b=f.sub.r, and m=1 where f.sub.r is a rotation frequency of the rotors, that a flux barrier of the rotor is defect.

8. The monitoring system according to claim 7, wherein the computer program comprises program code which, when executed by one or more of the at least one data processing device, causes one or more of the at least one data processing device to perform the step of: determining, on the basis that the first vibration frequency f.sub.b fulfils the following barrier fault condition: $f_b=\frac{f_s}{2p}$ where f.sub.s is a supply frequency and p is a number of stator pole pairs, that a flux barrier of the rotor is defect.

9. The monitoring system according to claim 7, wherein the monitoring system comprises a plurality of sensors arranged to measure vibration in at least three different radial directions of the stator, such as at least four, at least six or at least eight different radial directions of the stator, and wherein the control system is arranged to receive measurement signals from the plurality of sensors.

10. The monitoring system according to claim 7, wherein the computer program comprises program code which, when executed by one or more of the at least one data processing device, causes one or more of the at least one data processing device to perform the step of: determining that a flux barrier of the rotor is defect when the first vibration frequency and the mode shape fulfil the barrier fault conditions and when a vibration amplitude at the first vibration frequency exceeds a predetermined threshold value.

11. The monitoring system according to claim 7, wherein the determination whether the first vibration frequency and the mode shape fulfil the barrier fault conditions is performed continuously or repeatedly during operation of the synchronous reluctance electric machine.

12. The monitoring system according to claim 7, wherein the sensors are arranged to communicate wirelessly with the control system.

13. The monitoring system according to claim 7, wherein the sensors are accelerometers.

14. A synchronous reluctance electric machine comprising: a stator and a rotor, the rotor comprising a Plurality of magnetically conductive core elements stacked in an axial direction of the rotor, and each core element includes flux barriers a monitoring system including; a first sensor arranged to measure vibrations of the stator in a first radial direction of the stator; a second sensor arranged to measure vibrations of the stator in a second radial direction of the stator; and a control system comprising at least one data processing device and at least one memory having a computer program stored thereon, the computer program including a program code which, when executed by one or more of the at least one data processing device, causes one or more of the at least one data processing device to perform the steps of: detecting based on measurement signals from the first sensor and the second sensor, a first vibration frequency and a mode shape of the vibration at the first vibration frequency; and determining, on the basis that the first vibration frequency f.sub.b and the mode shape m fulfil the following barrier fault conditions:
f.sub.b=f.sub.r, and m=1 where f.sub.r is a rotation frequency of the rotor, that a flux barrier of the rotor is defect.

15. The monitoring system according to claim 14, wherein the computer program comprises program code which, when executed by one or more of the at least one data processing device, causes one or more of the at least one data processing device to perform the step of: determining, on the basis that the first vibration frequency f.sub.b fulfils the following barrier fault condition: $f_b=\frac{f_s}{2p}$ where f.sub.s is a supply frequency and p is a number of stator pole pairs, that a flux barrier of the rotor is defect.

16. The monitoring system according to claim 14, wherein the monitoring system comprises a plurality of sensors arranged to measure vibration in at least three different radial directions of the stator, such as at least four, at least six or at least eight different radial directions of the stator, and wherein the control system is arranged to receive measurement signals from the plurality of sensors.

17. The monitoring system according to claim 14, wherein the computer program comprises program code which, when executed by one or more of the at least one data processing device, causes one or more of the at least one data processing device to perform the step of: determining that a flux barrier of the rotor is defect when the first vibration frequency and the mode shape fulfil the barrier fault conditions and when a vibration amplitude at the first vibration frequency exceeds a predetermined threshold value.

18. The monitoring system according to claim 14, wherein the determination whether the first vibration frequency and the mode shape fulfil the barrier fault conditions is performed continuously or repeatedly during operation of the synchronous reluctance electric machine.

19. The monitoring system according to claim 14, wherein the sensors are arranged to communicate wirelessly with the control system.

20. The monitoring system according to claim 14, wherein the sensors are accelerometers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Further details, advantages and aspects of the present disclosure will become apparent from the following embodiments taken in conjunction with the drawings, wherein:

[0034] FIG. 1: schematically represents a cross-sectional side view of a synchronous reluctance electric machine;

[0035] FIG. 2: schematically represents a cross-sectional front view of section A-A in FIG. 1;

[0036] FIG. 3: schematically represents the synchronous reluctance electric machine comprising a monitoring system; and

[0037] FIG. 4: shows the first four mode shapes of vibration.

DETAILED DESCRIPTION

[0038] In the following, a method of identifying a fault in a synchronous reluctance electric machine, a monitoring system for identifying a fault in a synchronous reluctance electric machine, and a synchronous reluctance electric machine comprising a monitoring system, will be described. The same or similar reference numerals will be used to denote the same or similar structural features.

[0039] FIG. 1 schematically represents a cross-sectional side view of a synchronous reluctance electric machine 10. The machine 10 comprises a stator 12 and a rotor 14. The rotor 14 is rotatable about a rotation axis 16. The rotation axis 16 defines an axial direction of the rotor 14. FIG. 1 further shows windings 18 of the stator 12 and sensors, here exemplified as accelerometers 20.

[0040] The machine 10 of this example comprises a frame 22 fixed to the stator 12. The machine 10 further comprises bearings 24 and a shaft 26 fixed to the rotor 14. The shaft 26 is rotatable about the rotation axis 16.

[0041] The rotor 14 comprises a plurality of magnetically conductive core elements 28. In this example, each core element 28 has an identic design. The core elements 28 are stacked in the axial direction of the rotor 14. Moreover, the core elements 28 are compressed together in the axial direction. In this example, each core element 28 is a thin plate, the thickness in FIG. 1 being strongly exaggerated for illustrative purposes. The core elements 28 are made of a magnetically conductive material, such as electric steel having a high value of relative permeability.

[0042] FIG. 2 schematically represents a cross-sectional front view of section A-A in FIG. 1. As shown in FIG. 2, the core elements 28 are circular. Each core element 28 of the rotor 14 and therefore also the formed combination, i.e. rotor core, is operationally divided in sectorial sections. The number of sectorial sections defines the number of poles of the rotor 14. The rotor 14 of this example comprises four rotor poles, i.e. two rotor pole pairs. The stator 12 of this example comprises twelve stator poles, i.e. six stator pole pairs.

[0043] Each core element 28 comprises a plurality of magnetic flux barriers 30. As shown in FIG. 2, each rotor pole comprises four flux barriers 30, each flux barrier 30 being divided into two flux barrier sections separated by a narrow bridge in the middle. However, each rotor pole may comprise more or less than four flux barriers 30. Each flux barrier 30 may be an opening through the core element 28 (in the axial direction). The flux barriers 30 may be filled with air or with magnetically non-conductive material, such as aluminium, which has a lower relative permeability than the magnetically conductive material (such as electric steel) of the core elements 28.

[0044] FIG. 2 further shows that the core element 28 comprises tangential ribs 32. Each rib 32 is provided radially outside (with respect to the rotation axis 16) an end of a flux barrier 30. FIG. 2 further shows an air gap 34 between the rotor 14 and the stator 12.

[0045] In the context of the present disclosure, a breakage of a flux barrier 30 shall be construed to be equal with a breakage of a tangential rib 32.

[0046] Breakage of one flux barrier 30 of one core element 28 is typically associated with breakage of neighboring flux barriers 30 of adjacent core elements 28. When one of the flux barriers 30 breaks, the air gap 34 may be reduced. Thus, a broken flux barrier 30 risks to come into contact with the stator 12.

[0047] FIG. 3 schematically represents the synchronous reluctance electric machine 10 comprising a monitoring system 36. The monitoring system 36 is configured to identify a fault in the machine 10.

[0048] The monitoring system 36 comprises the accelerometers 20. The accelerometers 20 are configured to measure vibrations of the stator 12. As shown in FIG. 3, the monitoring system 36 of this example comprises eight accelerometers 20 evenly distributed around the circumference of the stator 12. A great number of accelerometers 20 enables an accurate determination of a mode shape of the vibration.

[0049] The monitoring system 36 further comprises a control system 38. The control system 38 comprises a data processing device 40 and a memory 42. The memory 42 has a computer program stored thereon. The computer program comprises program code which, when executed by the data processing device 40, causes the data processing device 40 to perform any step as described herein.

[0050] The monitoring system 36 of this example further comprises measurement cables 44, an amplifier 46 and an A/D converter 48. The accelerometers 20 are connected by the measurement cables 44 to the amplifier 46, and further to the A/D converter 48. The accelerometers 20 may alternatively be wireless, e.g. for online processing of vibration measurements from the accelerometers 20.

[0051] The accelerometers 20 provide vibration information in time space, i.e. the acceleration as a function of time. In addition, the angular position of each accelerometer 20 is known. The vibration measurements from the accelerometers 20 are stored in digital form in the memory 42 for further processing.

[0052] The data processing device 40 receives and processes the vibration measurements stored in the memory 42. To this end, the data processing device 40 may execute one or more computer programs stored in the memory 42. The computer program may comprise a two dimensions Fourier transform for determining a first vibration frequency and a mode shape. The computer program may further comprise program code for determining whether the first vibration frequency and the mode shape fulfil barrier fault conditions, as described herein.

[0053] Two dimensions Fourier transform, with respect to position (defined by the locations of the accelerometers 20) and with respect to time, is applied to the measurement results in order to reveal the mode shapes and the frequencies of the vibrations. The equation for the Fourier transform can be written as:

[00003]$a\left(\theta ,t\right)=\underset{m=0}{\overset{\infty }{.Math.}}\underset{n=0}{\overset{\infty }{.Math.}}\left[A_1.Math.\cos \left(m.Math.\theta +n.Math.\omega .Math.t\right)+A_2.Math.\cos \left(-m.Math.\theta +n.Math.\omega .Math.t\right)\right]$

[0054] wherein a=measured acceleration, θ=angular position along a perimeter of the stator 12, t=time, A=calculated coefficients of the acceleration, ω=supply frequency, and wherein m determines the mode shape and n determines the vibration frequency.

[0055] During operation of the machine 10, radial vibrations are generated. By means of the accelerometers 20, the radial vibrations of the rotor 14 can be measured since the vibrations of the rotor 14 are transmitted to the stator 12.

[0056] In case one of the flux barriers 30 breaks, the rotor 14 becomes dynamically eccentric (with respect to the rotation axis 16). A vibration of the rotor 14 at the rotational frequency of the rotor 14 will thereby be excited. This vibration has vibration mode 1. By monitoring also the vibration mode, in addition to the vibration frequency, a fault of the rotor 14 can be distinguished from mechanical vibrations. The monitoring system 36 enables not only the detection of the vibration frequencies, but also the detection of the mode vibration shapes, the so-called mode shapes. FIG. 4 shows the first four mode shapes of vibration.

[0057] During operation of the machine 10, the monitoring system 36 continuously or repeatedly monitors vibrations, determines a first vibration frequency based on a first vibration measurement in a first radial direction and/or a second vibration measurement in a second radial direction, determines a mode shape of the vibration at the first vibration frequency based on the first and second vibration measurements, and determines whether the first vibration frequency and the mode shape fulfils barrier fault conditions. The barrier fault conditions are defined as:

f.sub.b=f.sub.r, and m=1

[0058] where f.sub.b is the first vibration frequency, f.sub.r is the rotation frequency of the rotor 14, and m is the mode shape. If the barrier fault conditions are fulfilled, it is concluded that a flux barrier 30 is defect. Thus, by monitoring the vibration frequency and mode shape of the vibration of the rotor 14, a conclusive diagnostic can be given about the condition of the machine 10. Upon determining that a flux barrier 30 is defect, one or more preventive actions may be taken, such as automatic stopping of the machine 10.

[0059] While the present disclosure has been described with reference to exemplary embodiments, it will be appreciated that the present invention is not limited to what has been described above. For example, it will be appreciated that the dimensions of the parts may be varied as needed. Accordingly, it is intended that the present invention may be limited only by the scope of the claims appended hereto.