Modeling Approach and Fault Index Analysis of A Vo
Modeling Approach and Fault Index Analysis of A Vo
Modeling Approach and Fault Index Analysis of A Vo
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Abstract— This paper presents a modeling approach and a interest [5][6]. The acquired signals can be thermal, magnetic
fault index analysis of a voltage-source brushless DC motor. (magnetic field, flux density...), electrical (currents,
First, an analytical multi-physical model of the inverter-fed voltages,...) or mechanical (torque, vibration…) [7]. Among
Permanent Magnet DC motor is developed and simulated using these signals, vibration analysis has been one of the most
Matlab/Simulink. This model enables the generation of attractive and successful techniques for health monitoring of
electrical, magnetic and vibration signals under healthy and
rotating machines, as stated in [8][9].
faulty motor behaviors, with several fault categories and
severities. Before simulating faulty conditions in the different The crucial step in a signal-based FDI approach is the
parts of the analytical model, they are compared to Finite analysis of the process data in one or more informative
Element models, developed using Matlab for air-gap flux density domains (time, frequency...) to extract discriminative features
and ANSYS software for stator natural frequency calculations. sensitive to the fault occurrence, type and severity [5]. For this
Simulation results of the motor during normal functioning and purpose, the presented work focuses on the extraction of time,
under faulty conditions are presented. In particular, rotor space, frequency and harmonic indicators from EM vibration
eccentricity and single pole demagnetization faults are studied in signals generated by the motor, and to analyze them with
this paper. Then, different features, including time-, space-, respect to the operating condition and fault severity.
frequency- and harmonic- domain characteristics, are extracted
The main contribution of this paper is:
from vibration signals for different cases. Finally, these
indicators are analyzed with respect to the fault severity to select The design of an analytical model of an inverter-fed
the most discriminative one(s) allowing an efficient fault BLDC motor combining the electrical, magnetic and
detection and isolation. vibratory behaviors of the PM motor
The use of the stator vibration signal as an alternative
I. INTRODUCTION
solution for FDI purpose, when the electrical and
Mode FEA (Hz) Analy (Hz) Error (%) IV. SIMULATION RESULTS
0 3410,06 3346 1,87 The 36-slot 12-pole BLDCM, proposed in [20], is used as
2 165,93 155,77 6,12 a reference motor. It is driven by a 180°-commutated voltage
3 420,13 403,6 3,94 inverter with a voltage DC bus 𝑉𝐷𝐶 = 490 V at the nominal
4 715,98 697,3 2,61 speed 𝑁𝑛 = 668 tr/min. SE and DE faults with different
degrees (𝜖𝑠 and 𝜖𝑑 = 10, 25, 37, 45, 55, 67, 80, 93 %), partial
III. FAULTS MODELING IN THE ANALYTICAL MODEL
PM cracks in south and north poles with various severities (𝜖𝑝
The first step toward a data-based fault diagnosis is to = 10, 25, 45, 55, 67, 80, 93, 100 %) are simulated in the
simulate the faults in the model and then, to analyze their analytical model. Then, their effects are studied on different
effects on the analyzed signals. In this section, the REF and signals (current, vibration…).
DMF are modeled. Due to the machine symmetry, the effects of REF and DMF
DMF in the rotor PM on the three stator phases are almost the same. Fig. 3 gives
current waveforms in phase A, in the time (a) and the
The rotor PMs of a SM-PMSM could be demagnetized due frequency (b) domains, for a healthy, SE, DE, south and north
to high temperature levels, stator MMF or even by cracks pole cracks, cases. Based on this comparison, it is shown that
produced in rotor PMs during manufacturing [1]. the studied faults have no significant effects on the current
In the magnetic model, a crack is created in a rotor pole to signals, due to the winding configuration; so they cannot be
imitate the DMF. It is introduced by removing certain PM effectively detected by the conventional motor current
elements using an analytical signal (β(𝜃𝑟 )) in the 𝜃𝑟 -domain signature analysis (MCSA). As well, the EM torque has been
added to the 𝑀𝑀𝐹𝑟 . The mathematical equation of β(𝜃𝑟 ), studied under different cases. Fig.4 gives the 𝑇𝐸𝑀 waveforms
given in (8), depends on the angular position [𝜃j0 : 𝜃j1 ] in (rad) for a healthy, 45% SE, 45% DE and 45% crack, cases.
and the depth 𝜀𝑝 in (%) of the crack in the faulty pole “j”. 50
Healthy
40 10
1 45% SE
20 10 2
𝑚
Magnitude (A)
10
𝑗
𝐴0 = ((−1) 𝜀𝑝 𝑀𝑀𝐹𝑟,𝑚𝑎𝑥 (𝜃j1 − 𝜃j0 ))⁄(2𝜋) 0
10
-1
-20
(−1)𝑗 (𝜀𝑝 𝑀𝑀𝐹𝑟,𝑚𝑎𝑥 (sin(𝑚𝜃j1 ) − sin(𝑚𝜃j0 )))⁄(𝑚𝜋) -30 -3
10
𝐴𝑠,𝑚 = -40
-4
45% PDMF2
EM torque (N.m)
150
0
10
100
Frequency-domain indicators
-1
10
The frequency-domain indicators are extracted from the
50 10
-2 Fourier transform (X (f)) of the time signal ((𝑥𝑖 )𝑖=1,..,𝑁 )𝑗 . As
shown in fig.5 (b), the studied faults give rise to additional
frequencies 𝑓𝑘′ multiples of the mechanical frequency (𝑓𝑒 ⁄𝑝),
-3
0 10
0.18 0.182 0.184 0.186 0.188 0.19 0.192 0.194 0 100 200 300 400.8
Frequency (Hz)
where 𝑓𝑒 the electrical frequency and p is the number of pole
Time (sec)
(a) (b)
pairs. In this study, the frequency-domain indicators are the
Figure 4: Comparison between EM torque waveforms, in the time
(a) and the frequency (b) domains, for different cases. magnitudes “𝐴𝑓𝑘′ ” in (µm) of frequencies “𝑓𝑘′ ”.
The harmonic-domain indicators are extracted from the
6
Fourier transform (X (h)) of the space signal ((𝑥𝑗 )𝑗=1,..,𝑀 )𝑖 .
Healthy
10
0 45% PDMF
45% SE
2 As shown in fig.6 (b), the studied faults give rise to additional
4
-1
45% DE
45% PDMF1
space-harmonics “k”. The considered harmonic-domain
10
indicators are magnitudes “𝐴ℎ𝑘 ” in (µm) of harmonics “k”.
Vibration X(t) (µm)
Magnitude (µm)
-2
10
0 Results and discussions
-2 10
-3
Different time- and space-domains scalar indicators are
-4 -4
listed in Table II. In order to study the relevance of these
10
indicators, their relative values (𝐼𝑛𝑑𝑟 ) in (%) with respect to
-6
0.18 0.2 0.22 0.24 0.26 0 100 200 300 400
the healthy case (𝐼𝑛𝑑𝑎,ℎ ), calculated by (12), are considered
Time (sec) Frequency (Hz)
(a) (b)
instead of their absolute ones (𝐼𝑛𝑑𝑎 ).
Figure 5: Comparison between time-domain vibration signals (a) 𝐼𝑛𝑑𝑟 (%) = (𝐼𝑛𝑑𝑎 − 𝐼𝑛𝑑𝑎,ℎ )⁄𝐼𝑛𝑑 𝑎,ℎ × 100 (12)
and their frequency components (b) for different cases.
The frequency- and harmonic- domains indicators
6
(𝐴𝑓𝑘 ; 𝐴ℎ𝑘 ), in (µm) for k = {0, 1, 2, 3 and 4} are given in Table
Healthy
10
0
45% SE
45% DE
III. For the healthy case, dominant frequency and harmonic
4 45% PDMF1
components are {𝑚𝑝, 𝑛𝑓𝑒 } with m = {0, 2} and n = {0, 2, 4,
Vibration X(theta) (µm)
45% PDMF
2
2
6}. Indeed, “𝐴ℎ𝑘 ” for k = {0, 2p (12)} and “𝐴𝑓𝑘′ ” for k’ = {0,
Magnitude(µm)
-1
10
0
2p (12), 4p (24), 6p (36)} exist even for a healthy case while
10
-2
others are only produced by faults.
-2
The P-2-P and RMS values and “𝐴ℎ2 ” can effectively detect
-4
10
-3
the occurrence of a fault. They have almost increasing
monotonic evolutions in function of the fault gravity, with
-6 -4
0 60 120 180 240 300 360
10
0 1 2 3 4 5 6 7 8 9 10 11 12 13 high values compared to the healthy case. However, they are
Harmonic
Space (degree)
(a) (b) overlapping for different fault types and they can’t identify
the fault type. In addition, “𝐴ℎ1 ” gives the same result for a
Figure 6: Comparison between space-domain vibration signals (a)
and their harmonics (b), for different cases SE or DE with more important values compared to the crack
case. Therefore, it is an effective indicator for the eccentricity
V. FEATURE EXTRACTION AND ANALYSIS FROM case (SE or DE). The “𝐴𝑓2 ” gives an almost zero value for the
VIBRATION SIGNALS SE case. However, it’s significantly affected by both DE and
crack and it can be used to distinguish them from SE.
In this section, the set of vibration signals obtained for As fault degrees increase, the kurtosis, time domain “IF”
different fault types and severities, are analyzed in the time-, manifest almost the same behaviors for different faults with
more or less sensitivity. They have weak relative values with Table III: Evolution of frequency and harmonic indicators (µm) in function
of fault degrees (%)
respect to the healthy case, compared to other indicators.
Furthermore, their evolutions with fault severity are not FREQUENCY HARMONIC
monotonic and they are overlapping for different fault types. 1200
PDMF
1
25
PDMF
1
healthy case (around 25% for 100% of fault). Therefore, they 800 15
The magnitudes “𝐴𝑓0 ” and “𝐴ℎ3 ” (for 𝜎𝑠 > 0.5), the “CF” 400 5
(for 𝜎𝑠 > 0.4) and “IF” (for 𝜎𝑠 > 0.4) calculated in the space 200
0
0.7 DE DE
2 100 2
80 SE SE 0.4
DE 0.3
DE
70 0.3
80
0.2
60 0.2
50 60 0.1
0.1
40 0 0
0 20 40 60 80 100 0 20 40 60 80 100
40 18
30 25
PDMF
1
20 16 SE PDMF
20 1
DE
8
12 SE 16 SE 10
DE DE
14 6
10
12 4 5
8
10 2
6 8 0
0 0 20 40 60 80 100
0 20 40 60 80 100
6 1.2 9
4
PDMF PDMF
1 1
4
SE 8 PDMF
2 2
2 1 DE
𝐴𝑓3 ; 𝐴ℎ3 (µm)
SE
PDMF 7
0 2 DE
0 20 40 60 80 100 0
0 20 40 60 80 100 6
0.8
50 45
PDMF PDMF
1 1 5
PDMF 40 PDMF2
2 0.6
40 SE 4
SE
35
DE DE
0.4 3
30 30
Ku (%)
2
25
20 0.2
20
1
10 15 0 0
0 20 40 60 80 100 0 20 40 60 80 100
0.4 0.4
10 PDMF PDMF
0 1 1
0.35 PDMF 0.35 PDMF
5 2 2
𝐴𝑓4 ; 𝐴ℎ4 (µm)
SE SE
-10 0 0.3 DE 0.3 DE
0 20 40 60 80 100 0 20 40 60 80 100
14
150 x 10 0.25 0.25
6
100
SKEWNESS (%)
60 70
calculated in the time domain. Moreover, the magnitudes
50 60 “𝐴𝑓3 , 𝐴𝑓4 , 𝐴ℎ4 ” can be used to identify the partial crack in
PDMF
1
different poles.
CF (%)
40 50
PDMF
2
SE
30 40
DE The skewness of the vibration signals calculated in the time
20 30
PDMF
1
and space domains are given in row (4) of Table II. In the time
10 20
0
PDMF
SE
2
10
domain, the skewness under SE and DE are non-monotonic
-10
0 20 40 60
DE
80 100 0
for fault severities less the 60%; but significantly different for
0 20 40 60 80 100
120
PDMF
120 the crack case (around 120%). Moreover, the skewness in the
1
100 PDMF
SE
2 100 space domain for SE and DE are only overlapping for small
80 DE
80
faults (with a severity less than 15%). Over this value, this
IF (%)