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Uma adequada gestão das atividades de manutenção foca seus objetivos na confiabilidade e disponibilidade dos equipamentos, bem como na diminuição dos custos de reparo envolvidos. Visando contribuir neste sentido, o presente trabalho propõe um estudo de caso relacionado à análise de depreciação técnica e depreciação econômica dos equipamentos utilizados numa indústria de produção de papel imprensa. Especificamente, aplica-se a análise da curva de Weibull a uma base de dados de histórico de falhas ocorridas em motores elétricos existentes no processo produtivo e realiza-se, simultaneamente, uma análise de depreciação econômica desses equipamentos. O estudo envolveu a análise de 31 motores elétricos, classificados em 10 grupos de acordo com a potência de operação. A partir dos resultados obtidos para o coeficiente de forma correspondente a um período histórico de 20 anos de manutenção, bem como da análise de depreciação dos motores, foi possível verificar que mais de 50% dos motores analisados tiveram falhas do tipo mortalidade prematura e, o restante dos equipamentos, falhas do tipo fim de vida útil. Uma análise estatística de importância da correlação entre as variáveis de estudo indicou que, para o nível de confiança de 95%, a potência do motor elétrico não apresenta correlação significativa com o valor do fator de forma e nem com o número de manutenções corretivas realizadas. A única relação significativa foi encontrada entre o tamanho do motor e o custo das manutenções ou intervenções, como era esperado. O estudo realizado mostrou de uma maneira ágil e do ponto de vista da gestão da manutenção, uma análise técnica e econômica conjunta da vida útil de motores elétricos em relação à questão da sua depreciação e à escolha da melhor estratégia de manutenção a ser adotada. / An efficient management of maintenance activities is normally focused on reliability and availability of equipments, as well as in reducing the costs involved. Aiming to contribute in this sense, the present study proposes a case of study related to the analysis of technical and economic depreciation of electrical motors used in processes of a newsprint industry. In particular, both the Weibull distribution and an economic depreciation analysis were applied to a historic data base containing electric motor failures. The study was carried out for 31 electric motors, which were classified into 10 groups of electric powers. From results obtained for the form factor in 20 years of maintenance and the depreciation analysis was verified that more than 50% of electric motors had premature failures, whereas the rest of equipments had failures of useful life. A statistical analysis of correlation among variables showed that the power of the electric motor had no significance correlation with both the form factor and the number of failure events at 95% of confidence level. However, a significance correlation was found between the power of the electric motor and the maintenance cost involved, as expected. The study showed a practical way of a combined technical and economical analysis applied to electric motors for choosing the better maintenance strategy.

Abstract The aim of this research work is to develop a tool for condition monitoring of squirrel-cage motors using axial magnetic flux measurements, and to design a diagnostics system for electrical motors. The basic theory of the measurements and systems was found through literature reviews and was further developed from the experimental results of this research work. Fluxgate magnetometers and Hall effect sensors are not reliable enough for condition monitoring purposes, but measurements by flux coil sensors can reach adequate reliability. The useful frequency area of the flux coil sensor is from about 0.2 Hz to 15 kHz, an area is well applicable for condition monitoring of squirrel-cage motors. Output voltage is frequency dependent, increasing towards higher frequencies. Sufficient sensitivity is usually reached by a flux coil sensor having a diameter of about 30 cm and the number of turns of about 200. Sensitivity can be improved by increasing the diameter or number of turns of the coil. The sensor should be placed axially centred on the end of the motor, and measurements should be made with the loaded motor in steady operation. Output voltage is typically from the microvolt to millivolt level, however, installation inside the motor can increase it from tens of millivolts to some volts. The dynamic resolution requirement of measurement is about 70 dB and the highest line resolution needed for the spectrum analysis is about 3200 lines. Time base signal can be used to study rapid disturbances of flux caused by mechanical loading or switching of the frequency converter. Various motor failures cause specific variation to the frequency distribution of flux, so spectrum analysis is well applicable for condition monitoring. Reference measurement of each motor is required because stator winding factors, installation tolerances, operating conditions and mechanical load affect leakage flux. A broken rotor bar failure can be detected from the amplitude difference between the supply frequency and its rotor bar induced sideband. A broken rotor end ring failure can be detected by the amplitude difference between the slip frequency and the supply frequency. However, it was found that the stator current spectrum is a more reliable method of detecting both these rotor failures. The supply voltage asymmetry can also be evaluated by specific sidebands of axial flux. Turn to turn failure of the stator winding was most reliably detected by sidebands around the rotor slot pass frequencies. Equations for frequency converter supplied motors are the bases for similar equations, but the supply frequency is replaced by the output current frequency of the converter. The developed diagnostics system design for condition monitoring of ac motors includes stator current, flux coil, temperature, vibration, partial discharge, bearing current and voltage measurements. At the system diagnosis stage these measurable signals are divided to time base and frequency base signals and for each of them a fault indicator is determined. For flux coil measurements four fault indicators were found: rotor bar failure ratio, rotor end ring failure ratio, stator winding turn to turn ratio and supply voltage asymmetry operation ratio. With these failure indicators we determine failure location, state and cause. From this information a lifetime prediction of the motor is made. The results of this work are used to analyse flux coil measurements of squirrel-cage motors. In addition the research has led to a special application to monitor electric motors using an on-line condition monitoring system for paper machines and power plants.

M.Ing. / Shaft encoders, are devices generally used in speed and position control applications for sensing position of rotational and linearly moving objects. Most conventional shaft encoders operate on the principle of reading encoded information off a disk, which is fitted to the shaft or using resolver units. Problems are often experienced in fitting high-resolution encoder disks or resolvers to small motors or moving objects. The resolution of an encoder system, using an encoded disk, is a function of the maximum number of slots that are cut in the disk. If the disk itself has to be very small, physical constraints limit the accuracy of the encoder. However, any machined surface will have characteristic marks on it and it is believed that these marks can be used to obtain a unique analogue signature for the shaft. This analogue signature can then be used to gain further knowledge about the rotational speed and possibly the position of the shaft. This project was an investigation into the possibility of gaining accurate, absolute positional information for a rotating shaft. An optical source- and detector system is used in the process of observing the irregularities on the shaft surface. This signal data is gathered and processed using a technique, which compensates for variation in shaft speed during the period in which data is sampled. The entire algorithm, which calculates the absolute position of the shaft from the data gathered, was implemented on a digital signal processor board. Results were evaluated and the maximum non-linearity of the test system was found to vary between 1.8% and 3.7% of full-scale deflection. The resolution of the sensor was between 1.5 and 2.5 degrees with hysteresis between 1% and 1.5% of full scale deflection. The test system allows for rotation in any direction. Possible problems that might be encountered with this type of encoder system are pointed out in this report. Future developments and possible improvements are also discussed.

Recent failures of large induction machines due to rotor bar breaks have become a major industrial concern in South Africa. These failures have occurred while applying current condition monitoring methods. This would imply that current theories are either inadequate or badly implemented. This thesis investigates two currently used condition monitoring strategies which focus on monitoring the stator current and axial vibration to detect bar breaks as well as a third method which involves putting destructive shaft voltages to good use and using this signal to diagnose rotor defects. This document begins by familiarizing the reader with two conventional approaches which involve monitoring the stator current and the axial vibration to detect rotor bar breaks. Thereafter the origins of shaft voltage are discussed and its use as a condition monitoring tool is first theoretically derived and then validated by finite element simulations. A thorough discussion of the measurement equipment required is presented and ultimately the performance of these three methods is tested by means of a laboratory measurement as well as two on-site measurements. The results from these measurements suggest that when making proper use of both conventional condition monitoring methods, these methods have a 50% success rate in the detection of rotor bar breaks. The alternative method investigated, which involves monitoring the shaft voltage, has a 75% success rate in the detection of rotor bar breaks. This highlights the use of shaft voltage as a condition monitoring tool. / Dr. S. R. Holm Prof. W. A. Cronje

Orientador: Ely Carneiro de Paiva / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-27T21:55:57Z (GMT). No. of bitstreams: 1 MartinezArias_RonaldRicardo_M.pdf: 6818308 bytes, checksum: d91e74cb8827b9ee03bcb0e84ccc9bd0 (MD5) Previous issue date: 2014 / Resumo: No presente trabalho, o modelo dinâmico do dirigível do Projeto AURORA (Gomes e Ramos, 1998), (Azinheira et al., 2001) e (Azinheira et al., 2008) é adaptado para considerar 4 motores ao invés de 2 apenas. Além disso, esses motores possuem acionamento elétrico (DC-Brushless) ao invés de propulsão por motor de combustão. Esses motores poderão trabalhar em acionamento diferencial, ou seja, motores frente-trás ou esquerda-direita com forças de propulsão diferentes, com a finalidade de gerar momentos e forças que complementem os demais atuadores do dirigível, como as superfícies de cauda ou leme. Duas inovações principais caracterizam esse novo sistema. O primeiro ponto é a utilização de quatro propulsores vetorizáveis ao invés de apenas dois como o usual. O segundo ponto é a angulação de 20 [graus] presente na fixação dos propulsores. Essa angulação faz com que, ao ser vetorizado para cima, cada propulsor gere uma componente de força lateral, além das componentes longitudinal e vertical. Se a intensidade da força gerada em cada propulsor for a mesma, obviamente as forças laterais geradas num par de propulsores se cancelam, e temos uma situação parecida com a atuação clássica de dirigíveis, gerando forças apenas para frente e para cima. Mas se, por outro lado, as intensidades de força nos propulsores de um dado par (dianteiro ou traseiro) forem diferentes, então forças resultantes laterais (bem como momentos) podem ser obtidos no CV (Centro de Volume) do dirigível. Assim, se o par de propulsores dianteiros gera uma componente lateral de forças para a direita, por exemplo, e o par traseiro gera uma componente lateral para a esquerda, então temos a geração de um momento de guinada positivo (horário), supondo obviamente que os motores encontram-se vetorizados. Essa é a chamada propulsão diferencial esquerda-direita que permite a geração de momentos de guinada em baixas velocidades, de tal forma compensar a baixa eficiência aerodinâmica da cauda com pouca incidência de ar (vento relativo). Outra possibilidade é a geração da propulsão diferencial dianteira-traseira, onde ambos propulsores dianteiros fornecem força de igual intensidade, mas de amplitude diferente daquela gerada pelos propulsores traseiros. As forças laterais são canceladas, mas um novo momento de arfagem pode ser gerado, e com um grau de liberdade a mais do que na situação onde se usava apenas dois propulsores vetorizáveis. Podemos obter inclusive um momento de arfagem no dirigível e ainda mantê-lo na posição "nivelada" de ângulo de arfagem (pitch) nulo. O uso da propulsão diferencial dianteira-traseira permite também obter uma mudança contínua e suave nas forças e momentos ao se variar a velocidade de operação do dirigível (airspeed). Evita-se assim a transição brusca de atuação que é observada quando o dirigível, na configuração clássica de apenas dois motores, passa das baixas velocidades (usando vetorização) para as altas velocidades (dispensando vetorização). Dessa forma, tanto a propulsão diferencial lateral (esquerda-direita), como a longitudinal (traseira-dianteira) obtida com essa configuração inédita, permite gerar momentos e forças que complementam os demais atuadores do dirigível, como as superfícies de cauda ou leme. Ressalta-se que as diferentes configurações de propulsão motora como essa proposta aqui considerada (de domínio do Projeto DRONI) poderão aumentar a eficiência e desempenho das abordagens de controle linear e não linear já desenvolvidas previamente no âmbito do Projeto AURORA / Abstract: In this paper masters, the dynamic model of AURORA Project airship (Gomes e Ramos, 1998), (Azinheira et al., 2001) and (Azinheira et al., 2008) is adapted to consider 4 engines instead of 2. Furthermore, those engines as electric start (DC-Brushless) instead of propulsion combustion engine. Engines can work with differential start, that is, front-back or left-right engines with different thrust forces. It has the purpose of generating forces and torques which complement other airship actuators, such as the tail and rudder surfaces. Two main innovations characterize this new system. First, it uses four thrusters with thrust vector control instead of just two as usual. Second, it is the 20 [degrees] angulation that is present in the thrusters setting. This angulation allows each thruster generates a lateral force component besides the longitudinal and vertical components when thrusters are vectorized upward. If the amount of force generated in each thruster is the same, obviously, the addition of lateral forces generated in a pair of thrusters will be zero, and we will have a similar situation with the classic airship performance, generating forces only forward and up. But if the amount of force on thrusters on a given pair (front or back) are different, then resulting lateral force (and torques) can be obtained on airship CV (Volume Center). Thus, if the front pair of thrusters generates a lateral force component to the right, for example, and the rear pair generates a lateral component to the left, we have a generation of yaw torque positive (clockwise), obviously assuming that the engines are vectorized. This is called the differential thrust left-right which allows the generation of yaw torques on low speeds, in order to compensate a low aerodynamic efficiency of tail with little air effect (relative wind). Another possibility is the generation of the differential thrust front-back, where both front thrusters provide equal amount of force, but with a different amplitude than the force generated by the rear thrusters. The lateral forces are canceled, but a new pitch torque can be generated, and with a degree of freedom more than in the situation where it was used only two thrusters with thrust vector control. We can get even a pitch torque on the airship and still keeping it on null pitch angle position. The use of diferential thrust front-back allows also getting a slight and continuous change on the forces and torques when is varied the airship operation speed (airspeed). It avoids the abrupt transition of performance that is observed when the airship, on classic configuration of only two engines, goes through from low speeds (using vectoring) to high speeds (dispensing vectorization). Thus, both the differential thrust lateral (left-right) as the longitudinal (front-back) obtained with this configuration unprecedented, it allows to generate torques and forces that complementing the other airship actuators, such as tail surfaces or rudder. It should be noted that different confiurations of thrust (Project DRONI) may increase the efficiency and performance of linear control approaches and nonlinear previously carried out under the AURORA Project / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestre em Engenharia Mecânica

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The source-to-wheel efficiency of today’s electrified vehicles already far surpasses the efficiency of strictly gasoline vehicles. As sources of electricity become cleaner and more efficient, and as gasoline becomes more scarce, the need for transportation electrification is increasingly economically and environmentally driven. The automotive industry primarily makes use of permanent magnet synchronous machines (PMSMs) and induction machines (IMs), the latter has the cost advantage of containing no rare earth metals. This thesis studies two different induction motors for electrified powertrain applications using a novel optimization algorithm to create efficiency maps and compare the efficiencies of the two motors. Induction motors are difficult to banchmark due to their complicated control schemes. Each point in their operating range can be achieved with an infinite number of current/slip combinations and therefore has infinite potential efficiencies. The proposed algorithm limits the number of simulations needed to benchmark an induction machine, and provides a clear and unbiased way to compare machines based on losses at their most efficient current/slip combinations over their entire operating range. The proposed algorithm is able to calculate losses within 5% accuracy of simulation values for both machines. The first motor studied makes use of stranded windings and geometry parameters from the Tesla Motors patents. The efficiency map created has a peak efficiency of 96% and corresponds closely to an efficiency map for a similar motor found in literature. The second motor makes use of copper bar windings, which are easier to manufacture and have lower material costs. Bar windings, typically have lower resistance and stator copper losses at low speeds, but higher effective resistance and stator losses at high speeds due to eddy effects. The motor modelled was intended simply to compare the stranded and bar windings, and to see the advantages and disadvantages. For this reason, no other changes are made to the winding layout or motor geometry, including changes that would reduce the eddy effect. The resultant efficiency map has a peak efficiency of only 90%, performing worse than the stranded wound motor across most of its operating range. At very low speeds, under 1000 rpm, the efficiency of the bar wound machine is better than that of the stranded machine. The bar wound machine also has the advantage of being over 80% efficient everywhere. The author suggests that future research focus on applying the proposed benchmarking algorithm to stator bar motors designed to limit eddy effects. Strategies include changing the slot opening shape, increasing the number of stator bars, and moving the stator bars away from the air gap. / Thesis / Master of Applied Science (MASc)

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