Field winding fault diagnosis in DC motors during manufacturing using thermal monitoring

Abstract Quality assessment during DC motor manufacturing should involve quality controls designed to detect various fault conditions associated with the components included in the machine. Some defects, however, can be produced by the automatic manufacturing process during the assembly of the individual components. Inter-turn short-circuits, turn to earth short-circuits and open winding, among other fault conditions, can result from the field poles manufacturing and insertion inside the stator. The main problem with these kinds of faults is that though the motor is likely to be operational, there is a high probability of motor breakdown in the near future. In this paper, the above fault conditions are analyzed and a thermal model and an infrared monitoring test method for manufacturing quality control is proposed.

[1]  J. Penman,et al.  Detection and location of interturn short circuits in the stator windings of operating motors , 1994 .

[2]  Rolf Isermann,et al.  Application of model-based fault detection to a brushless DC motor , 2000, IEEE Trans. Ind. Electron..

[3]  H.A. Toliyat,et al.  Advanced fault diagnosis of a DC motor , 2004, IEEE Transactions on Energy Conversion.

[4]  Roderick Melnik,et al.  Computational analysis of temperature rise phenomena in electric induction motors , 2003 .

[5]  Hamid A. Toliyat,et al.  Condition monitoring and fault diagnosis of electrical machines-a review , 1999, Conference Record of the 1999 IEEE Industry Applications Conference. Thirty-Forth IAS Annual Meeting (Cat. No.99CH36370).

[6]  V. Sartre,et al.  Transient state study of electric motor heating and phase change solid-liquid cooling , 1997 .

[7]  Thomas G. Habetler,et al.  A Survey on Testing and Monitoring Methods for Stator Insulation Systems of Low-Voltage Induction Machines Focusing on Turn Insulation Problems , 2008, IEEE Transactions on Industrial Electronics.

[8]  Andrea Cavagnino,et al.  Solving the more difficult aspects of electric motor thermal analysis in small and medium size industrial induction motors , 2005 .

[9]  Jing Yang,et al.  Fault detection and diagnosis of permanent-magnet DC motor based on parameter estimation and neural network , 2000, IEEE Trans. Ind. Electron..

[10]  Maarten J. Kamper,et al.  Thermal modelling of an axial flux permanent magnet machine , 2004 .

[11]  P. K. Panday,et al.  Experimental study of the cooling of a closed type electric motor , 2000 .

[12]  M. M. Morcos,et al.  Automatic Fault Diagnosis of Electric Machinery: A Case Study in PM Brushless DC Motors , 2005 .

[13]  Chu Kiong Loo,et al.  An Effective Surveillance System Using Thermal Camera , 2009, 2009 International Conference on Signal Acquisition and Processing.

[14]  Swamidoss Sathiakumar,et al.  A new thermal model for EV induction machine drives , 1996, Power Electronics in Transportation.

[15]  Derek B. Ingham,et al.  Enhanced numerical model of performance of an encapsulated three-phase transformer in laboratory environment , 2007 .

[16]  A. Vallan,et al.  Evaluation of radiation thermal resistances in industrial motors , 2005, IEEE Transactions on Industry Applications.

[17]  Timothy J. E. Miller,et al.  Design of Brushless Permanent-Magnet Motors , 1994 .

[18]  Mo-Yuen Chow,et al.  Incipient Fault Detection In DC Machines Using A Neural Network , 1988, Twenty-Second Asilomar Conference on Signals, Systems and Computers.

[19]  Norimichi Kawashima,et al.  A new technique to measure the temperature of a rotating motor shaft , 2009 .

[20]  Andrea Cavagnino,et al.  Evolution and Modern Approaches for Thermal Analysis of Electrical Machines , 2009, IEEE Transactions on Industrial Electronics.