Vibration-based fault diagnosis (FD) with a simple spectrum can be complex, especially when considering FD of rotating machinery with multiple bearings like a multi-stage turbine. Various studies have sought to better interpret fault spectra, but the process remains equivocal. Consequently, it has been accepted that the simple spectra requires support from additional techniques, such as orbit analysis. But even orbit analysis can be inconclusive. Though promising, attempts at developing viable methods that rival the failure coverage of spectrum analysis without gaining computational complexity remain protracted. Interestingly, few researchers have developed FD methods for transient machine operation, however, these have proven to be involved. Current practices limit vibration data to a single machine, which usually requires a large unique data history. However, if sharing of data between similar machines with different foundations was possible, the need for unique histories would be mitigated. From readily available works, this has not been encountered. Therefore, a simple but robust vibration-based approach is warranted. In light of this, a novel on-bearing vibration response integration approach for condition monitoring of shaft-related faults irrespective of speed and foundation type is proposed in the present study. Vibration data are acquired at different speeds for: a baseline, unbalance, bow, crack, looseness, misalignment, and rub conditions on three laboratory rigs with dynamically different foundations, namely: rigid, flexible support 1 (FS1) and flexible support 2 (FS2). Testing is done on the rigid rig set up first, then FS1, and afterwards FS2. Common vibration features are computed from the measured data to be input to the proposed approach for further processing. First, the proposed approach is developed through its application to a machine at a steady speed in a novel Single-speed FD technique which exploits a single vibration sensor per bearing and fusion of features from different bearings for FD. Initially, vibration features are supplemented with bearing temperature readings with improved classification compared to vibration features alone. However, it is observed that temperature readings are insensitive to faults on the FS1 and FS2 rigs, when compared to vibration features, which are standardised for consistent classification on the different rigs tested. Thus, temperature is not included as a final feature. The observed fault classifications on the different rigs at different speeds with the standardised vibration features are encouraging. Thereafter, a novel Unified Multi-speed FD technique that is based on the initial proposed approach and which works by fusion of vibration features from different bearings at different speeds in a single analysis step for FD is proposed. Experiments on the different rigs repeatedly show the novel Multi-speed technique to be suitable for transient machine operation. Then, a novel generic Multi-foundation Technique (also based on the proposed approach) that allows sharing of vibration data of a wide range of fault conditions between two similarly configured machines with similar speed operation but different foundations is implemented to further mitigate data requirements in the FD process. Observations made with the rigs during steady and transient speed tests show this technique is applicable in situations where data history is available on one machine but lacking on the other. Comparison of experimental results with results obtained from theoretical simulations indicates the approach is consistent. Thus, the proposed approach has the potential for practical considerations.

Η παρούσα διπλωματική εργασία εκπονήθηκε στο τμήμα Ηλεκτρολόγων Μηχανικών και Τεχνολογίας Υπολογιστών του Πανεπιστημίου Πατρών. Το θέμα που πραγματεύεται είναι η μελέτη των τριφασικών ασύγχρονων μηχανών διπλού κλωβού με διαφορετικά υλικά στις αυλακώσεις του δρομέα. Τα κύρια αντικείμενα που ερευνώνται είναι δύο. Το πρώτο είναι η ανάλυση και η κατανόηση της ηλεκτρομαγνητικής συμπεριφοράς κινητήρων διπλού κλωβού με διαφορετικά υλικά στις αυλακώσεις του δρομέα. Το δεύτερο είναι η μελέτη σφαλμάτων δρομέα σε μηχανές διπλού κλωβού και οι μέθοδοι διάγνωσης αυτών. / This thesis was carried out at the Department of Electrical and Computer Engineering, University of Patras. The subject matter is the study of three-phase Asynchronous Double Cage Induction Motors with Different Rotor Bar Materials (motor double cage with different materials in the slots of the rotor). The main objects that are being investigated are two. The first is the analysis and understanding of the electromagnetic behaviour of double cage motors with different materials in the slots of the rotor. The second is the study of faults in the rotor in machines dual cage and the diagnostic methods.

Brushless Direct Current (BLDC) motors are one of the motor types rapidly gaining popularity. BLDC motors are being increasingly used in critical high performance industries such as appliances, automotive, aerospace, consumer, medical, industrial automation equipment and instrumentation. Fault detection and condition monitoring of BLDC machines is therefore assuming a new importance. The objective of this research is to advance the field of rotor and load fault diagnosis in BLDC machines operating in a variety of operating conditions ranging from constant speed to continuous transient operation. This objective is addressed as three parts in this research. The first part experimentally characterizes the effects of rotor faults in the stator current and voltage of the BLDC motor. This helps in better understanding the behavior of rotor defects in BLDC motors. The second part develops methods to detect faults in loads coupled to BLDC motors by monitoring the stator current. As most BLDC applications involve non-stationary operating conditions, the diagnosis of rotor faults in non-stationary conditions forms the third and most important part of this research. Several signal processing techniques are reviewed to analyze non-stationary signals. Three new algorithms are proposed that can track and detect rotor faults in non-stationary or transient current signals.

Os motores de indução desempenham um importante papel na indústria, fato este que destaca a importância do correto diagnóstico e classificação de falhas ainda em fase inicial de sua evolução, possibilitando aumento na produtividade e, principalmente, eliminando graves danos aos processos e às máquinas. Assim, a proposta desta tese consiste em apresentar um multiclassificador inteligente para o diagnóstico de motor sem defeitos, falhas de curto-circuito nos enrolamentos do estator, falhas de rotor e falhas de rolamentos em motores de indução trifásicos acionados por diferentes modelos de inversores de frequência por meio da análise das amplitudes dos sinais de corrente de estator no domínio do tempo. Para avaliar a precisão de classificação frente aos diversos níveis de severidade das falhas, foram comparados os desempenhos de quatro técnicas distintas de aprendizado de máquina; a saber: (i) Rede Fuzzy Artmap, (ii) Rede Perceptron Multicamadas, (iii) Máquina de Vetores de Suporte e (iv) k-Vizinhos-Próximos. Resultados experimentais obtidos a partir de 13.574 ensaios experimentais são apresentados para validar o estudo considerando uma ampla faixa de frequências de operação, bem como regimes de conjugado de carga em 5 motores diferentes. / Induction motors play an important role in the industry, a fact that highlights the importance of correct diagnosis and classification of faults on these machines still in early stages of their evolution, allowing increase in productivity and mainly, eliminating major damage to the processes and machines. Thus, the purpose of this thesis is to present an intelligent multi-classifier for the diagnoses of healthy motor, short-circuit faults in the stator windings, rotor broken bars and bearing faults in induction motors operating with different models of frequency inverters by analyzing the amplitude of the stator current signal in the time domain. To assess the classification accuracy across the various levels of faults severity, the performances of four different learning machine techniques were compared; namely: (i) Fuzzy ARTMAP network, (ii) Multilayer Perceptron Network, (iii) Support Vector Machine and (iv) k-Nearest-Neighbor. Experimental results obtained from 13.574 experimental tests are presented to validate the study considering a wide range of operating frequencies and also load conditions using 5 different motors.

Os motores de indução desempenham um importante papel na indústria, fato este que destaca a importância do correto diagnóstico e classificação de falhas ainda em fase inicial de sua evolução, possibilitando aumento na produtividade e, principalmente, eliminando graves danos aos processos e às máquinas. Assim, a proposta desta tese consiste em apresentar um multiclassificador inteligente para o diagnóstico de motor sem defeitos, falhas de curto-circuito nos enrolamentos do estator, falhas de rotor e falhas de rolamentos em motores de indução trifásicos acionados por diferentes modelos de inversores de frequência por meio da análise das amplitudes dos sinais de corrente de estator no domínio do tempo. Para avaliar a precisão de classificação frente aos diversos níveis de severidade das falhas, foram comparados os desempenhos de quatro técnicas distintas de aprendizado de máquina; a saber: (i) Rede Fuzzy Artmap, (ii) Rede Perceptron Multicamadas, (iii) Máquina de Vetores de Suporte e (iv) k-Vizinhos-Próximos. Resultados experimentais obtidos a partir de 13.574 ensaios experimentais são apresentados para validar o estudo considerando uma ampla faixa de frequências de operação, bem como regimes de conjugado de carga em 5 motores diferentes. / Induction motors play an important role in the industry, a fact that highlights the importance of correct diagnosis and classification of faults on these machines still in early stages of their evolution, allowing increase in productivity and mainly, eliminating major damage to the processes and machines. Thus, the purpose of this thesis is to present an intelligent multi-classifier for the diagnoses of healthy motor, short-circuit faults in the stator windings, rotor broken bars and bearing faults in induction motors operating with different models of frequency inverters by analyzing the amplitude of the stator current signal in the time domain. To assess the classification accuracy across the various levels of faults severity, the performances of four different learning machine techniques were compared; namely: (i) Fuzzy ARTMAP network, (ii) Multilayer Perceptron Network, (iii) Support Vector Machine and (iv) k-Nearest-Neighbor. Experimental results obtained from 13.574 experimental tests are presented to validate the study considering a wide range of operating frequencies and also load conditions using 5 different motors.