Stray Flux-Based Rotation Angle Measurement for Bearing Fault Diagnosis in Variable-Speed BLDC Motors

Angle of rotation is a key parameter in motor fault diagnosis under varying speed conditions, and is usually measured by an optical encoder. However, the use of encoders is intrusive and in many scenarios its signal is difficult to access due to technical or commercial reasons. In this study, a novel rotation angle measurement method based on stray flux analysis is proposed and applied to bearing fault diagnosis of brushless direct-current (BLDC) motors. The measurement accuracy of the proposed method is comparable to that from an encoder. The developed method is flexible, noninvasive, and nondestructive. It is easy to implement and eliminates the need for long cables and access of the motor control system. The proposed method can be extended to the diagnosis of motor electrical and drive faults. If implemented with an Internet of Things (IoT) or a hand-held device, it can further improve the reliability of sensorless motor drive systems in industrial automation so as to meet Industry 4.0 requirements.

[1]  Sylvain Meignen,et al.  A New Algorithm for Multicomponent Signals Analysis Based on SynchroSqueezing: With an Application to Signal Sampling and Denoising , 2012, IEEE Transactions on Signal Processing.

[2]  Lorand Szabo,et al.  Induction Machine Bearing Fault Detection by Means of Statistical Processing of the Stray Flux Measurement , 2015, IEEE Transactions on Industrial Electronics.

[3]  Wei Qiao,et al.  Current-Aided Order Tracking of Vibration Signals for Bearing Fault Diagnosis of Direct-Drive Wind Turbines , 2016, IEEE Transactions on Industrial Electronics.

[4]  Guang Meng,et al.  Nonlinear Chirp Mode Decomposition: A Variational Method , 2017, IEEE Transactions on Signal Processing.

[5]  Jianwen Shao,et al.  A novel microcontroller-based sensorless brushless DC (BLDC) motor drive for automotive fuel pumps , 2002, Conference Record of the 2002 IEEE Industry Applications Conference. 37th IAS Annual Meeting (Cat. No.02CH37344).

[6]  Kayhan Gulez,et al.  Stray magnetic field distributed around a PMSM , 2011, Turkish Journal of Electrical Engineering and Computer Sciences.

[7]  Weiwen Peng,et al.  Estimation of Bearing Remaining Useful Life Based on Multiscale Convolutional Neural Network , 2019, IEEE Transactions on Industrial Electronics.

[8]  Hau-Tieng Wu,et al.  The Synchrosqueezing algorithm for time-varying spectral analysis: Robustness properties and new paleoclimate applications , 2011, Signal Process..

[9]  Hongguang Li,et al.  An adaptive and tacholess order analysis method based on enhanced empirical wavelet transform for fault detection of bearings with varying speeds , 2017 .

[10]  Zhike Peng,et al.  Vision-Based Measurement System for Instantaneous Rotational Speed Monitoring Using Linearly Varying-Density Fringe Pattern , 2018, IEEE Transactions on Instrumentation and Measurement.

[11]  Wenping Cao,et al.  Non-invasive load monitoring of induction motor drives using magnetic flux sensors , 2017 .

[12]  Farhad Haghjoo,et al.  Turn to Turn Fault Detection, Discrimination, and Faulty Region Identification in the Stator and Rotor Windings of Synchronous Machines Based on the Rotational Magnetic Field Distortion , 2020, IEEE Transactions on Energy Conversion.

[13]  W. Hager,et al.  and s , 2019, Shallow Water Hydraulics.

[14]  Tianyang Wang,et al.  Rolling element bearing fault diagnosis via fault characteristic order (FCO) analysis , 2014 .

[15]  K. H. Lee,et al.  Comprehensive Analysis of Magnet Defect Fault Monitoring Through Leakage Flux , 2017, IEEE Transactions on Magnetics.

[16]  T.A. Lipo,et al.  Analysis and modeling of air-gap and zigzag leakage fluxes in a surface-mounted permanent-magnet Machine , 2004, IEEE Transactions on Industry Applications.

[17]  Angel Sapena-Bano,et al.  Diagnosis of Rotor Asymmetries Faults in Induction Machines Using the Rectified Stator Current , 2020, IEEE Transactions on Energy Conversion.

[18]  I. Daubechies,et al.  Synchrosqueezed wavelet transforms: An empirical mode decomposition-like tool , 2011 .

[19]  Hamid A. Toliyat,et al.  Performance Analysis of Synchronous Generators Under Stator Windings Ground Faults Near the Star Point - Experimental Verification , 2020, IEEE Transactions on Energy Conversion.

[20]  Yaguo Lei,et al.  Tacholess Envelope Order Analysis and Its Application to Fault Detection of Rolling Element Bearings with Varying Speeds , 2013, Sensors.

[21]  Bilal Akin,et al.  Discernment of Broken Magnet and Static Eccentricity Faults in Permanent Magnet Synchronous Motors , 2016, IEEE Transactions on Energy Conversion.

[22]  Athanasios N. Safacas,et al.  Deployment of an Adaptable Sensorless Commutation Technique on BLDC Motor Drives Exploiting Zero Sequence Voltage , 2015, IEEE Transactions on Industrial Electronics.

[23]  Yingjie Yu,et al.  Vision-based system for simultaneous monitoring of shaft rotational speed and axial vibration using non-projection composite fringe pattern , 2019, Mechanical Systems and Signal Processing.

[24]  Zhipeng Feng,et al.  Time-varying demodulation analysis for rolling bearing fault diagnosis under variable speed conditions , 2017 .

[25]  Siliang Lu,et al.  Tacholess Speed Estimation in Order Tracking: A Review With Application to Rotating Machine Fault Diagnosis , 2019, IEEE Transactions on Instrumentation and Measurement.

[26]  Chunhua Liu,et al.  Velocity Measurement Technique for Permanent Magnet Synchronous Motors Through External Stray Magnetic Field Sensing , 2018, IEEE Sensors Journal.

[27]  Reemon Z. Haddad.  Detection and Identification of Rotor Faults in Axial Flux Permanent Magnet Synchronous Motors Due to Manufacturing and Assembly Imperfections , 2020, IEEE Transactions on Energy Conversion.