EXPERT MOTOR CONDITION

MONITORING (EMCM)

procedures

Database

Signal conditioning

Data display, current

state, trends, alarms,

recommendation

Sensors

processed data

Client application Programs and other

systems

readings

Development engineers, programmers ...

Processing and working

unit

Execution

Norms, recommendations,

start phase

Traditional monitoring concept

Expert

Know-how transmission

Working

memory

Signal conditioning

Data display,

current state,

trends, alarms,

recommendation

Sensors learning

processed data

knowledge

Inference

module

Rules, procedures…

Client application

New

knowledge

Programs and other

systems, databases

readings

Development engineers, programmers ...

Knowledge

database

Processing and working

unit

Execution

Norms, recommendations,

start phase

FEM calculations and measurements

Expert monitoring concept

Information value from monitoring

Expert system provides additional value for users when it comes to predictive maintenance of the capital equipment.

inter-turn short circuit in the armature winding

presence of static eccentricity

termination of two rods of the cage rotor

bearing damage

Measured parameter has changed

“something is wrong” - Alarm

FEM calculations.

Calculation results.

Confirmation of calculations with experiments and industry applications.

NEW FAULT DETECTION METHODS (DMFM)

Analysis of calculated wave forms for correct and faulty machine conditions.

1

2

3

4

EMCM (EXPERT KNOWLEDGE IMPLEMENTED IN EMCM SYSTEM)

FEM Model

Finite Element Model (FEM) has been created to verify new algorithms in different loading conditions. Based on this model and real-world measurements, it has been demonstrated that accurate detection of shorted turns can be obtained without the need to vary the load on the machine if suitable sensors and algorithms are applied.

Expert knowledge for fault detection

Stator fault detection

1

Rotor fault detection

2

Differential measurement of the machine magnetic field enables fault detection

DMFM (Diferential Magnetic Field Measurement)

Patentted method for rotor broken bar detection or intercoil short circuit detection in rotor winding, based on diferential measurement of magnetic field using two measuring coils.

MEASURING VALUE (voltage) FAULT

voltage 0 V → no fault

voltage > 0 V → fault present

Detection of stator failure

Inter-coil short circuit current

Voltage of two serial connected coils

failure

No failure

failure

Detection of stator failure

Measurement coil 1

Measurement coil 2

Measurement coil for charging

Electronic circuit for failure detection

Applicable to induction machines with measurement coils

Rotor Failure Detection

Measurement coil 1

Measurement coil 2

Applicable to all types of induction machines

2

1

1

2 3

4

EMCM ( SYSTEM CONCEPT – FRONT END )

vibration

temperature

current

mag. field

1

2

3

4

Analog signals

EMCM ( SYSTEM CONCEPT )

EMCM

(standard communication)

Remote user

Ethernet

Sensors

EMCM detects: - one or more broken bars of the rotor cage - broken ring of the rotor cage - rotor eccentricity - bearing damage.

Local HMI

Remote web HMI

operator panel – HMI, web server – remote access,

database – data storage

Ethernet

measured data

system no. 1

USER

Ethernet

Ethernet

Ethernet

Ethernet

Firewall

EMCM ( INTEGRATION OF EMCM SYSTEMS – CONCEPT 1 )

system no. 2

system no. 3

measured

data

measured

data

USER

• AUTOMATED REPORT GENERATION

REPORTS AND DATA INTERPRETATION

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