Torsional vibration monitoring using induction machine electromagnetic torque estimation

The heavy duty drives need a continuous monitoring to avoid sudden loss of operation. In these systems, the mechanical anomalies like load troubles, great torque dynamic variations and torsional oscillations, result in the fatigue of the shaft driving electrical machine and other mechanical parts as bearings and gearboxes. Then, the permanent on-site mechanical performance has to be evaluated to predict the residual life time of each mechanical part on the base of combined mechanical loads affecting them. In this way, this paper proposes an electromagnetic torque estimation using non invasive measuring as a mean for mechanical monitoring of torsional stresses. Different electromagnetic torque estimations can be obtained from the induction machine mathematical representation and the simplest one in term of implementation is proposed for grid or inverter-fed machines. A test-bed based on a 5.5 kW squirrel-cage connected to a wound-rotor 4 kW induction machine via a gearbox has been used to validate the proposed method.

[1]  K. Reichard,et al.  Using torsional vibration analysis as a synergistic method for crack detection in rotating equipment , 2004, 2004 IEEE Aerospace Conference Proceedings (IEEE Cat. No.04TH8720).

[2]  Bertrand Raison,et al.  Models for bearing damage detection in induction motors using stator current monitoring , 2008, 2004 IEEE International Symposium on Industrial Electronics.

[3]  T.G. Habetler,et al.  A Nonintrusive and In-Service Motor Efficiency Estimation Method using Air-Gap Torque with Considerations of Condition Monitoring , 2006, Conference Record of the 2006 IEEE Industry Applications Conference Forty-First IAS Annual Meeting.

[4]  Ivor R. Smith,et al.  Fast calculation of harmonic torque pulsations in a VSI/induction motor drive , 1993, IEEE Trans. Ind. Electron..

[5]  Robert L. Hyde,et al.  Starting Characteristics of Electric Submergible Oil Well Pumps , 1986, IEEE Transactions on Industry Applications.

[6]  M. Dalva,et al.  Combined electrical and mechanical model of electric submersible pumps , 2001 .

[7]  Humberto Henao,et al.  Harmonic characteristics of an induction machine connected to a distribution network , 2002, IEEE 2002 28th Annual Conference of the Industrial Electronics Society. IECON 02.

[8]  Mario Guagliano.  Fatigue failure of a bar of a twin-screw extruder for plastics , 2005 .

[9]  Jyh-Cherng Gu,et al.  Effects of voltage harmonics on the electrical and mechanical performance of a three-phase induction motor , 1998, 1998 IEEE Industrial and Commercial Power Systems Technical Conference. Conference Record. Papers Presented at the 1998 Annual Meeting (Cat. No.98CH36202).

[10]  J. S. Hsu,et al.  Comparison of induction motor field efficiency evaluation methods , 1996, IAS '96. Conference Record of the 1996 IEEE Industry Applications Conference Thirty-First IAS Annual Meeting.

[11]  Jan Stein,et al.  The Torsional Stress Analyzer for Continuously Monitoring Turbine-Generators , 1980, IEEE Transactions on Power Apparatus and Systems.

[12]  James H. Holdrege,et al.  AC Induction Motor Torsional Vibration Consideration - A Case Study , 1983, IEEE Transactions on Industry Applications.

[13]  D.G. Ramey,et al.  Vulnerability of Large Steam Turbine Generators to Torsional Interactions During Electrical Grid Disturbances , 2007, IEEE Transactions on Power Systems.

[14]  H. Henao,et al.  Gearbox Monitoring Using Induction Machine Stator Current Analysis , 2007, 2007 IEEE International Symposium on Diagnostics for Electric Machines, Power Electronics and Drives.

[15]  A. H. Bonnett,et al.  Root cause AC motor failure analysis with a focus on shaft failures , 2000 .

[16]  D. J. Sheppard.  Torsional vibration resulting from adjustable-frequency AC drives , 1988 .

[17]  Joachim Holtz,et al.  Sensorless control of induction motor drives , 2002, Proc. IEEE.

[18]  Marko Hinkkanen,et al.  Modified integrator for voltage model flux estimation of induction motors , 2001, IECON'01. 27th Annual Conference of the IEEE Industrial Electronics Society (Cat. No.37243).

[19]  O.V. Thorsen,et al.  Failure identification and analysis for high voltage induction motors in petrochemical industry , 1998, Conference Record of 1998 IEEE Industry Applications Conference. Thirty-Third IAS Annual Meeting (Cat. No.98CH36242).

[20]  D.N. Walker,et al.  Torsional Vibration and Fatigue of Turbine-Generator shafts , 1981, IEEE Transactions on Power Apparatus and Systems.

[21]  J. M. Starkey,et al.  A torsional vibration measurement system , 1992 .

[22]  Jao-Hwa Kuang,et al.  THEORETICAL ASPECTS OF TORQUE RESPONSES IN SPUR GEARING DUE TO MESH STIFFNESS VARIATION , 2003 .

[23]  Charles B. Mayer.  Torsional Vibration Problems and Analyses of Cement Industry Drives , 1981, IEEE Transactions on Industry Applications.

[24]  H. Kubota,et al.  DSP-based speed adaptive flux observer of induction motor , 1991, Conference Record of the 1991 IEEE Industry Applications Society Annual Meeting.

[25]  R. Lorenz,et al.  A physically insightful approach to the design and accuracy assessment of flux observers for field oriented induction machine drives , 1992 .

[26]  K. Reichard,et al.  A Non-Intrusive Technique f or On-Line Shaft Crack Detection a nd Tracking , 2005, 2005 IEEE Aerospace Conference.

[27]  S. Kulig,et al.  Measurement and assessment of torsion oscillations in turbogenerators by using a torque sensor and robust observer , 2003, IECON'03. 29th Annual Conference of the IEEE Industrial Electronics Society (IEEE Cat. No.03CH37468).

[28]  F. Filippetti,et al.  Monitoring of induction motor load by neural network techniques , 2000 .

[29]  Chanan Singh,et al.  Report of Large Motor Reliability Survey of Industrial and Commercial Installations, Part II , 1985, IEEE Transactions on Industry Applications.

[30]  John S. Joyce,et al.  Torsional Fatigue of Turbine-Generator Shafts Caused by Different Electrical System Faults and Switching Operations , 1978, IEEE Transactions on Power Apparatus and Systems.

[31]  I. Takahashi,et al.  High-performance direct torque control of an induction motor , 1989 .

[32]  Peter Vas,et al.  Sensorless vector and direct torque control , 1998 .

[33]  Werner Leonhard,et al.  Control of Electrical Drives , 1990 .

[34]  Jan Melkebeek,et al.  Speed sensorless direct torque control of induction motors using an adaptive flux observer , 1999, Conference Record of the 1999 IEEE Industry Applications Conference. Thirty-Forth IAS Annual Meeting (Cat. No.99CH36370).

[35]  Report of Large Motor Reliability Survey of Industrial and Commercial Installations, Part I , 1985, IEEE Transactions on Industry Applications.

[36]  A. A. Shaltout,et al.  Analysis of torsional torques in starting of large squirrel cage induction motors , 1994 .

[37]  Nguyen Van Khang,et al.  Modelling Parametric Vibration of Gear-Pair Systems as a Tool for Aiding Gear Fault Diagnosis , 2004 .

[38]  Dong-Seok Hyun,et al.  An improved stator flux estimation for speed sensorless stator flux orientation control of induction motors , 1998, PESC 98 Record. 29th Annual IEEE Power Electronics Specialists Conference (Cat. No.98CH36196).