System And Method For Motor Fault Detection Using Stator Current Noise Cancellation
Abstract:
A system and method for detecting incipient mechanical
motor faults by way of current noise cancellation is
disclosed. The system includes.a controller configured
to detect indicia of incipient mechanical motor faults.
The controller further includes a processor programmed
to receive a baseline set of current data from an
operating motor and define a noise component in the
baseline set of current data. The processor is also
programmed to acquire at least on additional set of
real-time operating current data from the motor during
operation, redefine the noise component present in each
additional set of real-time operating current data, and
remove the noise component from the operating current
data in real-time to isolate any fault components
present in the operating current data. The processor is
then programmed to generate a fault index for the
operating current data based on any isolated fault
components.
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Notices, Deadlines & Correspondence
EATON CENTER, 1111 SUPERIOR AVENUE, CLEVELAND, OH 44114-2584, UNITED STATES OF AMERICA
Inventors
1. ZHOU, WEI
9400 EXPOSITION BLVD., APT. 107 LOS ANGELES, CA 90034 U.S.A.
2. LU, BIN
11110 75TH STREET #311, KENOSHA, WI 53142 U.S.A.
3. NOWAK, MICHAEL, P.
N51 W16724 FAIR OAK PARKWAY, MENOMONEE FALLS, WI 53213 U.S.A.
4. DIMINO, STEVEN, A.
8152 RICHMOND COURT, WAUWATOSA, WI 53213 U.S.A.
Specification
SYSTEM AND METHOD FOR MOTOR FAULT DETECTION USING
STATOR CURRENT NOISE CANCELLATION
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation-in-part of, and claims priority to,
U.S. non-provisional application serial number 12/132,056, filed June 3, 2008, and U.S.
provisional application Serial number 60/932,742, filed June 4, 2007, which are both
incorporated herein by reference. .
GOVERNMENT LICENSE-RIGHTS
[0002] The present invention was made at least in part with Government support
under Contract No. DE-FC36-04GO14000, awarded by the United States Department of
Energy. The Government may have certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] The present invention relates generally to motors and, more particularly, to a
system and method for detection of incipient conditions indicative of motor faults.
[0004] Three-phase induction motors consume a large percentage of generated
electricity capacity. Many applications for this "workhorse" of industry are fan and
pump industrial applications. For example, in a typical integrated paper mill, low
voltage and medium voltage motors may comprise nearly 70% of all driven electrical
loads. Due to the prevalence of these motors in industry, it is paramount that the three-
phase motor be reliable. Industry reliability surveys suggest that motor failures
typically fall into one of four major categories. Specifically, motor faults typically
result from bearing failure, stator turn faults, rotor bar failure, or other general
faults/failures. Within these four categories: bearing, stator, and rotor failure account
for approximately 85% of all motor failures.
[0005] It is believed that this percentage could be significantly reduced if the driven
equipment were better aligned when installed, and remained aligned regardless of
changes in operating conditions. However, motors are often coupled to misaligned
pump loads or loads with rotational unbalance and fail prematurely due to stresses
imparted upon the motor bearings. Furthermore, manually detecting such fault causing
conditions is difficult at best because doing so requires the motor to be running. As
such, an operator is usually required to remove the motor from operation to perform a
maintenance review and diagnosis. However, removing the motor from service is
undesirable in many applications because motor down-time can be extremely costly.
[0006] As such, some detection devices have been designed that generate feedback
regarding an operating motor. The" feedback is then reviewed by an operator to
determine the operating conditions of the motor. However, most systems that monitor
operating motors merely provide feedback of faults that have likely already damaged
the motor. As such, though operational feedback is sent to the operator, it is usually too
late for preventive action to be taken.
[0007] Some systems have attempted to provide an operator with early fault warning
feedback. For example, vibration monitoring has been utilized to provide some early
misalignment or unbalance-based faults. However, when a mechanical resonance
occurs, machine vibrations are amplified. Due to this amplification, false positives
indicating severe mechanical asymmetry are possible. Furthermore, vibration-based
monitoring systems typically require highly invasive and specialized monitoring
systems to be deployed within the motor system.
[0008] In light of the drawbacks of vibration-based monitoring, current-based
monitoring techniques have been developed to provide a more inexpensive, non-
intrusive technique for detecting bearing faults. There are also limitations and
drawbacks to present current-based fault detection. That is, in current-based bearing
fault detection, it can be challenging to extract a fault signature from the motor stator
current. For different types of bearing faults, fault signatures can be in different forms.
According to general fault development processes, bearing faults can be categorized as
single-point defects or generalized roughness. Most current-based bearing fault
detection techniques currently in use today are directed toward detecting single-point
defects and rely on locating and processing the characteristic bearing fault frequencies
in the stator current. Such techniques, however, may not be suitable for detecting
generalized roughness faults. That is, generalized-roughness faults exhibit degraded
bearing surfaces, but not necessarily distinguished defects and, therefore, characteristic
fault frequencies, may not necessarily exist in the stator current. As many bearing faults
initially develop as generalized-roughness bearing faults, especially at an early stage, it
would be beneficial for current-based bearing fault detection techniques to be able to
detect such generalized-roughness bearing faults.
[0009] It would therefore, be desirable to design a current-based bearing fault
detection technique that overcomes the aforementioned drawbacks. A current-based
bearing fault detection technique that allows for detection of generalized-roughness
bearing faults would be beneficial-, by providing early stage detection of bearing faults.
BRIEF DESCRIPTION OF THE INVENTION
[0010] The present invention provides a system and method for detecting impending
mechanical motor faults by way of current noise cancellation. Current data is
decomposed into a non-fault component (i.e., noise) and a fault component, and noise-
cancellation is performed to isolate the fault component of the current and generate a
fault identifier.
[0011] In accordance with one aspect of the invention, a controller configured to
detect indicia of incipient mechanical motor faults includes a processor programmed to
receive a first set of real-time operating current data from a motor during operation,
define a noise component present in the first set of real-time operating current data, and
generate a fault index for the first set of real-time operating current data based on any
isolated fault components. The processor is further programmed to acquire at least one
' additional set of real-time operating, current data from the motor during operation,
redefine the noise component present in each of the at least one additional sets of real-
time operating current data, remove the redefined noise component from each of the at
least one additional sets of real-time operating current data to identify any fault
components present therein, and generate a fault index for each of the at least one
additional sets of real-time operating current data based on any isolated fault
components.
[0012] In accordance with another aspect of the invention, a non-invasive method for
detecting impending faults in electric machines includes acquiring a plurality of stator
current data sets from the electric machine during operation, configuring a current data
filter for each of the plurality of stator current data sets, and applying each of the current
data filters to its respective stator current data set in real-time to generate a noise-
cancelled stator current. The method also includes determining a fault index from the
noise-cancelled stator current for each of the plurality of stator current data sets,
monitoring a value of the fault index for each of the plurality of stator current data sets,
and generating an alert if the value of a pre-determined number of fault indices exceeds
a control limit.
[0013] In accordance with yet another aspect of the invention, a system for
monitoring current to predict faults includes at least one non-invasive current sensor
configured to acquire stator current data from an operating motor. The system also
includes a processor connected to receive the stator current data from the at least one
non-invasive current sensor. The processor is programmed to repeatedly receive a set of
real-time operating current data from the at least one non-invasive current sensor, where
the set of real-time operating data is representative of real-time motor operation. The
processor is further programmed to define a non-fault component from each of the
repeatedly received sets of real-time operating current data, the non-fault component
being a periodic component of the real-time operating current data, and remove the non-
fault component from each of the sets of real-time operating current data in real-time to
isolate residual current data. The processor is also programmed to process the residual
current data to identify possible bearing faults, generate a fault index for any identified
bearing faults, and generate an alert if the fault index exceeds a fault index threshold.
[0014] Various other features and advantages of the present invention will be made
apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The drawings illustrate preferred embodiments presently contemplated for
carrying out the invention.
[0016] In the drawings:
[0017] FIG. 1 is a schematic representation of a motor assembly contemplated for
carrying out the invention.
. [0018] FIG. 2 is a block diagram of a controller in accordance with the invention.
[0019] FIG. 3 is a block diagram of a controller for configuring of a Wiener filter in
accordance with an embodiment of the invention.
[0020] . FIG. 4 is a block diagram of a controller for performing fault detection using
current noise cancellation in accordance with an embodiment of the invention.
{0021] FIG. 5 is a graphical representation of plotted fault index data relative to fault
index thresholds according to a statistical process control technique in accordance with
an embodiment of the invention.
[0022] FIG. 6 is a block diagram of a controller in accordance with another
embodiment of the invention.
[0023] FIG. 7 is a flow chart illustrating a technique for fault detection using current
noise cancellation in accordance with an embodiment of the invention.
[0024] FIG. 8 is a flow chart illustrating a technique for fault detection using current
noise cancellation in accordance with another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] The embodiments of the invention set forth herein relate to the detection of
abnormal conditions to predictively determine potential motor faults. Current signature
analysis (CSA) is utilized to review raw data received from a plurality of sensors of a
controller monitoring an operating motor. The system, which is preferably disposed
within the controller, decomposes the sensed/monitored current into a non-fault
component and a fault. component, and performs a noise-cancellation operation to
isolate the fault component of the current and generate a fault identifier. An operator of
the monitored motor system is then proactively alerted' of a potential fault prior to a fault
occurrence.
[0026] Referring now to FIG. 1, a motor assembly, such as an induction motor, is
configured to drive a load. The motor assembly 10 Includes a motor 12 that receives
power from a power supply 14. The motor assembly 10 also includes a controller 16
(i.e., current monitoring system) used to monitor, .as well as control, operation of the
motor 10 in response to operator inputs or motor fault conditions. The motor 12 and the
controller 16 typically are coupled to electronic devices such as a power controller, or
starter 17, and are in series with the motor supply to control power to the motor 12. The
controller 16 includes a processor 18 that, as will be described in greater detail with
respect to FIG. 2, implements an algorithm to determine the presence of unwanted
mechanical conditions and predictively alert an operator of a potential fault before a
fault occurs. The controller 16 further includes current sensors 22. According to an
exemplary embodiment of the invention, it is understood that current sensors 22 are
existing sensors used to also monitor current input to the motor and generally monitor
motor operation. That is, a separate set of current sensors for acquiring current data for
use in the noise-cancellation system/technique of the invention (described in detail
below) are not required. Thus, the acquisition of current data via current sensors 22 for
use in the noise-cancellation system/technique is understood to form a "sensorless"
current monitoring system/technique for predictively determining potential motor faults.
As is generally known, current data may be acquired from only two of the phases of a
three-phase motor as current data for the third phase may be extrapolated from the
current data of the monitored two phases. While the present invention will be described
with respect to a three-phase motor, the present invention is equivalently applicable to
other motors. Additionally, while shown as including a pair of current sensors 22, it is
also envisioned that a single current sensor could be used to acquire only one phase of
current.
[0027] In one embodiment of the invention, current sensors 22 acquire stator current
data from an induction motor. The stator current data acquired from sensors 22 is
communicated to processor 18, where the current is analyzed using CSA to detect .
Incipient (i.e., pending) motor faults, such as a bearing fault. As the identification of
characteristic fault frequencies is not a viable solution for detection of all types of
bearing faults (e.g., generalized roughness faults), according to an embodiment of the
invention, processor 18 is programmed to treat the fault detection problem as a low
signal-to-hoise ratio (SNR) problem. Processor 18 is thus programmed to decompose
the stator current into noise components and fault components (i.e., the bearing fault
signal). The noise components are the dominant components in the stator current, and
include supply fundamental frequencies and harmonics, eccentricity harmonics, slot
harmonics, saturation harmonics, and other components from unknown sources,
including environmental noises. Since these dominant components exist before and
after the presence of a bearing fault, a large body of the information they contain is not
related to the fault. In this sense, they can be treated as "noise" for the bearing fault
detection problem. As the "noise" could be 104 times stronger than the bearing fault
signal (i.e., tens of Amperes vs. milli-Amperes), the detection of the bearing fault signal
constitutes a low SNR problem. For solving the low SNR problem, processor 18
implements a noise cancellation technique/process for detecting the bearing fault signal.
The noise components in the stator current are estimated and then cancelled by their
estimates in a real-time fashion, thus providing a fault indicator from the remaining
components.
[0028] While processor 18 is shown as being included in a stand-alone controller 16,
it is also recognized that processor 18 could be included in power control/starter 17.
Additionally, it is recognized that processor 18 could be included in another power
control device such as a meter, relay, or drive. That is, it is understood that controller
16 could comprise an existing power control device, such as a meter, relay, starter, or
motor drive, and that processor 18 could be integrated therein.
[0029] Referring now to FIG. 2, a more detailed block diagram of controller 16 is
shown. As stated with respect to FIG. 1, the controller 16 includes processor 18 and
current sensors 22. Furthermore, the relay assembly 16 includes a notch filter 24, a low
pass filter 26, and an analog to digital (A/D) converter 28. The notch filter 24, low pass
filter 26, and A/D convertor 28 operate to receive raw data generated by current sensors
22 and .prepare the raw data for processing by processor 18. That is, filters 24 and 26
are used to eliminate the fundamental frequency (e.g., 60Hz in US and 50Hz in Asia)
and low frequency harmonics, as these harmonic contents are not related to bearing
failure. Removing such frequencies (especially the base frequency component) from
the measured .current data can greatly improve the analog -to-digital conversion
resolution and SNR, as the 60Hz frequency has a large magnitude in the frequency
spectrum of the current signal. While controller 16 is shown as including filters 24, 26,
it is also envisioned, however, that current data could be passed directly from current
sensors 22 to the A/D convertor 28.
[0030} As shown in FIG. 2, processor 18 functions, at least in part, as a noise
cancellation system that decomposes the stator current into noise components and fault
components. Processor 18 thus includes an input delay 30 and a current predictor 32,
with the current predictor 32 configured to predict noise components present in the
stator current. Subtracting the prediction of the noise components from repeatedly
acquired real-time stator current yields fault components which are injected into the
stator current by bearing failures/faults.' It is envisioned that current predictor 32 can be
configured as a Wiener filter (infinite impulse response (IIR) or fixed impulse response
(FIR)), a steepest descent algorithm, a least mean square (LMS) algorithm, a least
recursive squares (LRS) algorithm, or other digital filter.
[0031] Referring now to FIG. 3, in an exemplary embodiment of the invention,
processor 34 includes therein a Wiener filter 36 that provides for noise cancellation in
the stator current and isolation of a fault signal therein. To provide accurate noise
cancellation in the stator current, processor 34 is programmed to configure Wiener filter
36 to accurately define (i.e., estimate) most noise components in the stator current, such
that the fault signal in the stator current is not included in its output. In configuring the
Wiener filter 36, processor 34 analyzes the stator current data associated with healthy
bearing conditions. This stator current data associated with healthy bearing conditions
can include a first set of stator current data that is acquired, for example, within a short
period after the installation of a bearing or at the start of a bearing condition monitoring
process, thus ensuring that no bearing fault component is included in the stator current..
The first set of stator current data thus comprises baseline current data that essentially
contains pure noise data that does not include fault information.
[0032] The first set of stator current data, or baseline current data, is received by
processor 34 and is implemented for. configuring Wiener filter 36. More specifically,
the baseline current data is used for assigning coefficients in the Wiener filter 36.
Processor 34 assigns coefficients to the Wiener filter 36 such that the prediction error,
e(n), of the filter is minimized in the mean-square sense. As shown in FIG. 3, the
' baseline current data is described by:
where d1(n) is the noise components, d(n) is the fault signal, and v1(n) is the
measurement noise. As set forth above, the baseline current data is devoid of a fault
signal, and as such, Eqn. 1 reduces to x(n) = d1(n)+v1(n).
[0033] In configuring the Wiener filter 36, the processor 34 assigns the coefficients
of the filter by using the minimum mean-squared error (MMSE) method. In
implementing/applying the MMSE method, processor 34 solves for the coefficients,
w(k), k=0, 1,..., p, to minimize the mean square prediction error,ξ according to:
[0036] By assuming that the signal x(n) is wide-sense stationary (WSS), then:
[0037] The autocorrelation sequences in Eqn. 9 can be estimated by time averages
when implementing this method. For finite data records (i.e., a finite number of stator
current data points), x(n), 0 < n