A grande aplicação residencial de motores de indução monofásicos é em sistemas de refrigeração doméstica/comercial. O desenvolvimento de motores mais eficientes, associado ao controle de velocidade, fez com que, dentro os mais diversos tipos de motores, o motor síncrono de imã permanente tornasse objeto para a criação de uma metodologia de projeto, construção e realização de ensaios. Assim, para adequar o projeto do motor MSIP para substituição do motor de indução monofásico, foram feitos estudos de como aproveitar as laminações já existentes, através de definições das características básicas do estator e do rotor. O imã permanente a ser utilizado foi definido principalmente em função do custo do material e de suas propriedades magnéticas estarem adequadas à necessidade do projeto. O projeto magnético foi feito para maximizar o fluxo nos dentes, considerando as características construtivas e a curva de trabalho dos imãs. O projeto elétrico, a partir de um circuito equivalente do motor, permitiu explicar as relações de torque, corrente e tensão do motor MSIP, bem como a definição das bobinas do motor, quanto ao espaçamento destas entre as ranhuras, o cálculo do número de espiras e o diâmetro dos fios em função da área permitida pela ranhura da lamina do estator. Com as informações obtidas após o cálculo do motor MSIP, passou-se a construção de um protótipo constituído pelo estator, rotor e um sistema de suporte que permitisse o levantamento dos parâmetros do motor. Os parâmetros necessários foram definidos levando-se em consideração a necessidade para o projetista do conversor elétrico, sendo estes dados utilizados em simulações computacionais para a determinação do projeto do acionador. Com isto, os ensaios do motor MSIP permitiram o levantamento dos seguintes parâmetros: resistência, indutância, curvas de tensão de fase e linha da eletromotriz por velocidade em diversas rotações, momento de inércia e atrito viscoso, concluindo assim a proposta deste trabalho, e finalizando a metodologia para o motor MSIP. / A major residential application of single-phase induction motors is in domestic refrigeration. The development of more efficient motors, associated with speed control, has made that, among the most diverse types of electrical motors, the permanent magnet synchronous machine becomes an object of study for a design, construction and testing methodology. Therefore, to suit the PMSM design to replace the single phase induction motor, studies were made on how to take advantage of existing laminations, through definitions of the basic characteristics of the stator and rotor. The permanent magnet used was defined mainly as a function of the cost of the material and its magnetic properties since they suit the design requirements. PMSM magnetic design was made to maximize the magnetic flow in the slots considering the constructive characteristics and the magnet curve. The electric design, starting from a motor equivalent circuit, allowed to explain torque, current and voltage of the PMSM motor, as well as the definition of the motor windings regarding their filling in the slots, the calculation of coil number and the wire diameter as a function of the area allowed by the stator lamination slot. With the information obtained after the PMSM motor calculation, a prototype construction was initiated consisting of the stator, rotor and a support system to allow determining the motor parameters. The required parameters were defined taking into account the need the designer had of an electronic drive had. This data was used in computational simulations to determine the electronic driver design. After this, the motor testing allowed to identify the parameters, namely: winding resistance and inductance, various speed curves versus phase to phase and line voltage for back emf´s, moment of inertia and viscous friction, thus completing this work proposal, finalizing the project methodology for PMSM motor.

The aim of the thesis is to focus on the different methods of analysis of vibration signals. Focusing on the physical fundamentals of vibrations and a description of their origin in an electrical machine. Describe the vibration sources from mechanical across the electromagnetic to the aerodynamic. Defining the current defects of electric machines and sensors suitable for the measurement of vibrations in an electric machines. Introduction to the methods of analysis of vibration signals in the time and frequency domain. Then using some of these methods for the analysis of vibration signals measured asynchronous motors with different manufacturer defined production defect. The conclusion is composed from the comparison between measured and analyzed results.

Esta tese consiste em desenvolver um sistema de identificação e classificação de falhas em motores de indução trifásico. As falhas analisadas foram simuladas em laboratório e envolvem problemas elétricos, como curto-circuito no estator, e problemas mecânicos, como barras quebradas no rotor. O sistema computacional proposto é formado pela transformada discreta wavelet, pelo cálculo de variáveis estatísticas e por redes neurais artificiais. A partir dos sinais elétricos da corrente do estator, a transformada wavelet produz os coeficientes característicos das falhas, os quais são usados no cálculo das variáveis estatísticas, como a média, root mean square, skewness e kurtosis. Estes valores são transmitidos como dados de entrada para as redes neurais que identificam as falhas e classificam a natureza das mesmas. Por fim, resultados obtidos visam validar a metodologia sugerida, que buscou nos sistemas inteligentes soluções eficazes para diagnosticar falhas em máquinas elétricas. / This thesis consists in developing a system for the identification and classification of faults in three-phase electric motors. The faults were analyzed and simulated in the laboratory and involve electrical problems, such as short circuit in the stator, and mechanical problems, such as broken rotor bars. The proposed computer system is formed by discrete wavelet transform, by calculation of statistical variables and for artificial neural networks. From the electrical signals of the stator current, the wavelet transform produces characteristic coefficients of faults, which are extracted by calculating of statistics variables, such as mean, root mean square, skewness and kurtosis. These values are passed as input to the neural networks that identify faults and the severity of it. Finally, results aimed at validating the methodology suggested that sought effective solutions in intelligent systems to diagnose faults in electrical machines.

This thesis is part of a major research project to analyse vibro-acoustic characteristics from variable speed inverter driven induction motors (VSIDIM). The overall projects??? aimed at providing a better understanding of the mechanisms of sound generation from electromagnetic origins and developing a numerical model to predict the sound power emitted from a VSIDIM. The scope of this thesis is to assess experimentally the effect of various controller strategies on the radiated sound power and to develop a finite element method for calculating the electromagnetic force distribution over the stator. Various sources of noise in induction motors and their behaviour with speed and load have been reviewed. Models of the electromagnetic field and vibro-acoustic character have been discussed. An outline of various techniques of reducing noise in induction motors through design of inverters and modifications to the motor structure has been given. Experiments were conducted to assess the effect of controller strategies on the radiated sound power. Three different supplies were tested: a dynamotor which produces an almost sinusoidal supply with very low harmonic content, an inverter with a low switching frequency (less than 1kHz) and an inverter with a high switching frequency (8kHz) and various levels of random modulation. Results indicate that the sound power level of the MSC drive is a lot higher than that of the VSC 2000 drive and the dynamotor drive. The sound power level of the VSC 2000 drive and the dynamotor drive increases almost linearly with motor speed, that for the MSC drive is almost independent of speed. The sound power level of the MSC drive is almost 28dB higher than that of the dynamotor drive at 450rpm and the difference is reduced to 14dB at 1500rpm where the aerodynamic noise becomes more dominant. It has been found that at the rated speed (1500rpm), the sound power level varies by less than 3dB from no load to full load for all three sources. Although increasing the switching frequency increases the cost of the inverters and switching losses, results from the MSC and VSC 2000 drives clearly show that it reduces the radiated sound power by shifting the harmonics into higher and inaudible frequency range. The tonal nature around the switching frequency has been reduced by increasing the levels of random modulation to spread the energy over a wider range of frequencies, although the sound power level has not varied by more than 0.2dB. A finite element model has been developed to calculate the electromagnetic force distribution. The quasi-static solution method has been implemented by stepping the rotor through the time domain using a fine regular mesh in the air gap. The stator currents were experimentally obtained while the rotor currents were obtained using a 4 parameter state space model of the motor. Results of the simulation indicate the influence of stator and rotor slots, saturation and time harmonics in the current. The calculated electromagnetic force distribution has been used in a FEM/BEM acoustic model and SEA acoustic model to predict the radiated sound power which agrees reasonably well with the measured sound, thus validating indirectly the electromagnetic force simulations.

With the advent of power electronics, inverter-driven induction motor are finding increased use in industries because of applications that demand variable speed operations and because of the potential savings in energy usage. However, these drives sometimes produce unacceptably high levels in vibration and acoustic noise. A literature survey has revealed that while there has been intensive research on the design of inverters to minimize acoustic noise radiation from these drives, the vibro-acoustic behaviour of an induction motor structure has received relatively little attention. The primary objective of this research project, therefore, is to develop a general strategy/algorithm for estimating the acoustic noise radiated from inverter-driven induction motors. By using a three-phase, 2.2 kW induction motor, the vibration modes due to various structural components (such as the rotor, the stator/casing, the endshields and the base plate) of the motor structure were analysed by experimental modal testing. Results indicate that the vibration modes due to the rotor are only important at low frequencies. It has been found that the power injection method gives more accurate measurement of the damping of a motor structure than the modal testing and the time decay methods. If a point force excitation is used, then it is more accurate to measure the sound radiation efficiency than the power conversion efficiency for motor structures. The effect of three different inverter designs (an ideal ???almost sinusoidal??? controller and two commercially available PWM inverters) on the radiated acoustic power were assessed for both no-load and load conditions using sound intensity measurements conducted in an anechoic room. The results indicate that although the sound power level due to aerodynamic and mechanical noise increases at a rate of 12 dB per doubling of the motor speed, the electromagnetic noise dominates at low motor speeds and is still a significant noise source even at high motor speeds. For inverters with low switching frequencies, the radiated sound power level is almost 15 dB higher than the ideal case at low speeds and is relatively insensitive to the motor speed. For inverters that implement the random modulation technique, the change in the total sound power level with the level of the random modulation is very small but the tonal nature of the noise is greatly reduced. The vibration behaviour of a motor structure was modeled using the finite element method (FEM) and validated using the experimental modal testing results. It has been found that it is essential to model the laminated stator as an orthotropic structure. While the details of other structural components (such as the endshields, the teeth in the stator and the windings) are not so important, it is essential that they are incorporated into the structural model as simplified structures to account for their mass, stiffness and boundary conditions imposed on the motor structure. Based on this structural model, the radiated acoustic power for various operating conditions has been predicated using the boundary element (BEM) and the electromagnetic force calculated from an electromagnetic finite element model. The predicted results agree reasonably well with experimental measurements. Despite the success of the FEM/BEM approaches, they can be prohibitively expensive (in terms of computer resources required) to apply to large motors and high frequencies. Thus the feasibility of using a statistical method, namely, the statistical energy analysis (SEA), to estimate the radiated acoustic sound power from an inverter-driven induction motor has been examined. In order to carry out this analysis, analytical expressions for calculating the natural frequencies and radiation efficiency of finite length circular cylindrical shells (which are simplified models of the stator and casing of a motor structure) were firstly derived. The internal loss factors and coupling loss factors of the motor structure were determined experimentally using the power injection method. Then by introducing an equivalent surface mobility of circular cylindrical shells for the electromagnetic force, the vibration response and the acoustic noise radiated from each part of the motor structure were estimated. Results indicate that SEA method is potentially an efficient and effective tool in estimating the noise radiated from inverter-driven induction motors.

Stator current spectral analysis techniques are usually used to detect rotor faults in induction machines. Magnetic field anomalies in the airgap due to the rotor faults result in characteristic side-band harmonic components in the stator current spectrum, which can be measured as rotor fault signatures. A position-varying load torque oscillation at multiples of the rotational speed, however, has exactly the same effect. Stator current harmonics due to a load torque oscillation often obscure and even overwhelm rotor eccentricity fault detection since the magnitude of load oscillation induced harmonics is usually much larger. Although previous research has suggested some methods to differentiate between these two effects, most of them rely heavily on the accurate estimation of motor parameters. The objective of this research is to develop a far more practical and computationally efficient method to detect rotor faults effectively in the presence of a load torque oscillation. A significant advantage of the proposed scheme is that it does not need any knowledge of motor parameters. The normalized negative sequence information induced by a mixed rotor eccentricity in the stator current or terminal voltage space vector spectra, serves as a reliable rotor fault indicator to eliminate load oscillation effects. Detailed airgap magnetic field analysis for an eccentric motor is performed and all machine inductance matrices as well as their derivatives are reformulated accordingly. Careful observation of these inductance matrices provides a fundamental understanding of motor operation characteristics under a fault condition. Simulation results based on both induction motor dynamic model and Maxwell 2D Finite Element Model demonstrate clearly the existence of the predicted rotor fault indicator. Extensive experimental results also validate the effectiveness and feasibility of the proposed detection scheme.

The validity of transfer matrix method (TMM) employed in a nonlinear gear cam system is studied in this thesis. The nonlinear dynamic responses of each part in the nonlinear system are estimated by applying the 4th-order Runge-Kutta method. A high speed gear cam drive automatic die cutter was analyzed in this study. A 25 horsepower AC induction motor is designed to drive the system. To complete the cutting work, a sequential process of the harmonic motion and the intermittent motion are generated by the elbow mechanism and the gear cam mechanism, respectively. A simplified branched multi-rotor system is modeled to approximate the motion of the system. The variation of the dynamic parameters of the system in a loading cycle is estimated under a branched torsional system. The Holzer¡¦s transfer matrix method is used to study the variation of the system parameters during the intermittent movement. Moreover, the effect of time-varied speed introduced from the torque variation of the induction motor and gear cam mechanism on the nonlinear dynamic response of the system has also been investigated. To explore the dynamic effect of different cam designs, three different cam motion curves and seven operating rates have been analyzed in this work. The residual vibration of the last sprocket has also been discussed. Numerical results indicate that the proposed model is available to simulate the dynamic responses of a nonlinear gear cam drive system.

This dissertation proposes several simple, robust, and non-intrusive condition monitoring methods for induction motors fed by closed-loop inverters and claw-pole generators with built-in rectifiers. While the flexible energy forms synthesized by power electronic converters greatly enhance the performance and expand the operating region of induction motors and claw-pole generators, they also significantly alter the fault behavior of these electric machines and complicate the fault detection and protection. In this dissertation, special characteristics of the connected closed-loop inverter and rectifier have been thoroughly analyzed, with particular interest in their impact on fault behaviors of the induction motor and the claw-pole generator. Based on the findings obtained from the theoretical and experimental analysis, several sensorless thermal, mechanical, and insulation monitoring methods are proposed by smartly utilizing special features and capabilities of the connected power electronic converter. A simple and sensitive stator turn-fault detector is proposed for induction motors fed by closed-loop inverter. In addition, a stator thermal monitoring method based on active DC current injection and direct voltage estimation is also proposed to prevent the closed-loop controlled induction motors from thermally overloading. The performance of both methods is demonstrated by extensive experimental results. Methods to detect serpentine belt slip, serpentine belt defect, rotor eccentricity have been proposed for claw-pole generators using only the available electric sensor information. Methods to detect and protect stator turn faults in claw-pole generators are also presented in this dissertation. Lastly, a novel method to detect the generalized bearing roughness fault is proposed. All the proposed condition monitoring techniques have been validated by experimental results.

Modeling, fault assessment, and diagnostics of rolling element bearings and induction motors were studied. Dynamic model of rolling element bearings with faults were developed using vector bond graphs. The model incorporates gyroscopic and centrifugal effects, contact deflections and forces, contact slip and separations, and localized faults. Dents and pits on inner race, outer race and balls were modeled through surface profile changes. Experiments with healthy and faulty bearings validated the model. Bearing load zones under various radial loads and clearances were simulated. The model was used to study dynamics of faulty bearings. Effects of type, size and shape of faults on the vibration response and on dynamics of contacts in presence of localized faults were studied. A signal processing algorithm, called feature plot, based on variable window averaging and time feature extraction was proposed for diagnostics of rolling element bearings. Conducting experiments, faults such as dents, pits, and rough surfaces on inner race, balls, and outer race were detected and isolated using the feature plot technique. Time features such as shape factor, skewness, Kurtosis, peak value, crest factor, impulse factor and mean absolute deviation were used in feature plots. Performance of feature plots in bearing fault detection when finite numbers of samples are available was shown. Results suggest that the feature plot technique can detect and isolate localized faults and rough surface defects in rolling element bearings. The proposed diagnostic algorithm has the potential for other applications such as gearbox. A model-based diagnostic framework consisting of modeling, non-linear observability analysis, and parameter tuning was developed for three-phase induction motors. A bond graph model was developed and verified with experiments. Nonlinear observability based on Lie derivatives identified the most observable configuration of sensors and parameters. Continuous-discrete Extended Kalman Filter (EKF) technique was used for parameter tuning to detect stator and rotor faults, bearing friction, and mechanical loads from currents and speed signals. A dynamic process noise technique based on the validation index was implemented for EKF. Complex step Jacobian technique improved computational performance of EKF and observability analysis. Results suggest that motor faults, bearing rotational friction, and mechanical load of induction motors can be detected using model-based diagnostics as long as the configuration of sensors and parameters is observable. / text

The final work of master studies reviews various industrial robots constructions and parameters, from which they are characterized. Robotics systems and control of flexible production have been discussed in here. Various robots’ drives and their control advantages and disadvantages are analyzed. In the practical part original robot global movement platform is suggested and algorithm of two flexible production bays handling is created. Static characteristics of linear drive used in platform are calculated. Using software package “Matlab Simulink” model of symmetrical linear induction motor (LIM) is created and dynamic characteristics are gained. Concluding part presents inferences and suggestions.