Electrical Systems 1 E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Wissenschaft und neue Technologien
• Sprache: Englisch

Seitenzahl: 273

Veröffentlichungsjahr: 2020

Beschreibung

Methods of diagnosis and prognosis play a key role in the reliability and safety of industrial systems. Failure diagnosis requires the use of suitable sensors, which provide signals that are processed to monitor features (health indicators) for defects. These features are required to distinguish between operating states, in order to inform the operator of the severity level, or even the type, of a failure. Prognosis is defined as the estimation of a system�s lifespan, including how long remains and how long has passed. It also encompasses the prediction of impending failures. This is a challenge that many researchers are currently trying to address. Electrical Systems, a book in two volumes, informs readers of the theoretical solutions to this problem, and the results obtained in several laboratories in France, Spain and further afield. To this end, many researchers from the scientific community have contributed to this book to share their research results.

Leseprobe

Table of Contents

Cover

Introduction

1 Diagnostic Methods for the Health Monitoring of Gearboxes

1.1. Introduction

1.2. Identification of critical components in gearboxes

1.3. Diagnostic methodology

1.4. Methods of analysis

1.5. Monitoring methods

1.6. Diagnostic methods

1.7. Conclusion

1.8. References

2 Techniques for Predicting Defects in Bearings and Gears

2.1. Introduction

2.2. Prediction

2.3. Conclusion

2.4. References

3 Electrical Signatures Analysis for Condition Monitoring of Gears

3.1. Introduction

3.2. Gear torsional vibration effects on EMSs

3.3. Modeling gears in complex electromechanical systems

3.4. Modeling gear tooth surface damage faults

3.5. Online condition monitoring of gears in complex electromechanical systems

3.6. Conclusion

3.7. References

4 Modal Decomposition for Bearing Fault Detections

4.1. Introduction

4.2. Condition monitoring of electrical machines

4.3. Signal processing tools

4.4. Mode decomposition-based notch filters

4.5. Fault detectors

4.6. Simulation and experimental validation

4.7. Conclusion

4.8. References

5 Methods for Lifespan Modeling in Electrical Engineering

5.1. Introduction

5.2. Parametric methods

5.3. Nonparametric models

5.4. Conclusion

5.5. References

List of Authors

Index

Summary of Volume 2

End User License Agreement

Guide

Cover

Table of Contents

Begin Reading

Pages

v

iii

iv

ix

x

xi

xii

xiii

xiv

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

83

84

85

86

87

88

89

90

91

92

93

94

95

96

97

98

99

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

200

201

202

203

204

205

206

207

208

209

210

211

212

213

215

216

217

218

219

220

221

223

224

225

226

227

Electrical Systems 1

From Diagnosis to Prognosis

Edited by

Abdenour Soualhi

Hubert Razik

First published 2020 in Great Britain and the United States by ISTE Ltd and John Wiley & Sons, Inc.

Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms and licenses issued by the CLA. Enquiries concerning reproduction outside these terms should be sent to the publishers at the undermentioned address:

ISTE Ltd27-37 St George’s RoadLondon SW19 4EUUK

www.iste.co.uk

John Wiley & Sons, Inc.111 River StreetHoboken, NJ 07030USA

www.wiley.com

© ISTE Ltd 2020

The rights of Abdenour Soualhi and Hubert Razik to be identified as the authors of this work have been asserted by them in accordance with the Copyright, Designs and Patents Act 1988.

Library of Congress Control Number: 2019955247

British Library Cataloguing-in-Publication DataA CIP record for this book is available from the British LibraryISBN 978-1-78630-465-0

Introduction

The diagnosis and prognosis of electrical systems is still a relevant field of research. The research that has been carried out over the years has made it possible to acquire enough knowledge, to build a base from which we can delve further into this field of research. This study is a new challenge that estimates the remaining lifetime of the analyzed process. Many studies have been carried out to establish a diagnosis of the state of health of an electric motor, for example. However, making a diagnosis is like giving binary information: the condition is either healthy or defective. Of course, this may seem simplistic, but detecting a failure requires the use of suitable sensors that provide signals. These will be processed to monitor health indicators (features) for defects. Then, we witnessed a multitude of research activities around classification. It was indeed appropriate to distinguish the operating states, to differentiate them from one another and to inform the operator of the level of severity of a failure or even of the type of failure among a predefined panel. A major effort has been made to estimate the remaining lifetime or even the lifetime consumed. This is a challenge that many researchers are still trying to meet.

This book, which has been divided into two volumes, informs readers about the theoretical approaches and results obtained in different laboratories in France and also in other countries such as Spain, and so on. To this end, many researchers from the scientific community have contributed to this book by sharing their research results.

Chapter 1, Volume 1, “Diagnostic Methods for the Health Monitoring of Gearboxes”, by A. Soualhi and H. Razik, presents state-of-the-art diagnostic methods used to analyze the defects present in gearboxes. First of all, there is a bibliographical presentation regarding different types of gears and their defects. We conclude that gear defects represent the predominant defect at this level, thus justifying the interest in detecting and diagnosing them. Then, we present various gear analyses and monitoring techniques proposed as part of the condition-based maintenance and propose a diagnostic method. Thus, we show the three main phases of diagnosis: First, the analysis presented as a set of technical processes ensuring control of the representative quantities of operation; then the monitoring that exploits the fault indicators for detection; finally, the diagnosis which is the identification of the detected defect.

Chapter 2, Volume 1, “Techniques for Predicting Defects in Bearings and Gears”, by A. Soualhi and H. Razik, deals with strategies based on features characterizing the health status of the system to predict the appearance of possible failures. The prognosis of faults in a system means the prediction of the failure imminence and/or the estimation of its remaining life. It is in this context that we propose, in this chapter, the three methods of prognosis. In the first method, the degradation process of each system is modeled by a hidden Markov model (HMM). In a measured sequence of observations, the solution consists of identifying among the HMMs the one that best represents this sequence which allows predicting the imminence of the next degradation state and thus the defect of the studied system. In the second method (evolutionary Markov model), the computation of the probability that a sequence of observations arrives at a degradation state at the moment t+1, given the HMM modeled from the same sequence of observations, also allows us to predict the imminence of a defect. The third method predicts the imminence of a fault not by modeling the degradation process of the system, but by modeling each degradation state.

Chapter 3, Volume 1, “Electrical Signatures Analysis for Condition Monitoring of Gears in Complex Electromechanical Systems,” written by S. Hedayati Kia and M. Hoseintabar Marzebali, deals with a review of their most remarkable research, which has been carried out in the last 10 years. A particular emphasis has been placed on the topic of noninvasive fault detection in gears using electrical signatures analysis. The main aim is to utilize the electrical machine as a sensor for the identification of gear defects. In this regard, a universal approach is developed for the first time by the authors which allows evaluating the efficacy of noninvasive techniques in the diagnosis of torsional vibration induced by the faulty gear located within the drive train. This technique can be considered an upstream phase for studying the feasibility of gear fault detection using noninvasive measurement in any complex electromechanical system.

Chapter 4, Volume 1, “Modal Decomposition for Bearing Fault Detection”, by Y. Amirat, Z. Elbouchikri, C. Delpha, M. Benbouzid and D. Diallo, deals with induction machine bearing faults detection based on modal decomposition approaches combined to a statistical tool. In particular, a comparative study of a notch filter based on modal decomposition, through an ensemble empirical mode decomposition and a variational mode decomposition, is proposed. The validation of these two approaches is based on simulations and experiments. The achieved simulation and experimental results clearly show that, in terms of fault detection criterion, the variational mode decomposition outperforms the ensemble empirical mode decomposition.

Chapter 5, Volume 1, “Methods for Lifespan Modeling in Electrical Engineering”, by A. Picot, M. Chabert and P. Maussion, deals with the statistical methods for electrical device lifespan modeling from small-sized training sets. Reliability has become an important issue in electrical engineering because the most critical industries, such as urban transports, energy, aeronautics or space, are moving toward more electrical-based systems to replace mechanical- and pneumatic-based ones. In this framework, increasing constraints such as voltage and operating frequencies enhance the risk of degradation, particularly due to partial discharges (PDs) in the electrical machine insulation systems. This chapter focuses on different methods to model the lifespan of electrical devices under accelerated stresses. First, parametric methods such as design of experiments (DoE) and surface responses (SR) are suggested. Although these methods require different experiments to organize in a certain way, they reduce the experimental cost. In the case of nonorganized experiments, multilinear regression can help estimate the lifespan. In the second part, the nonparametric regression tree method is presented and discussed, resulting in the proposal of a new hybrid methodology that takes advantages of both parametric and nonparametric modeling. For illustration purpose, these different methods are evaluated on experimental data from insulation materials and organic light-emitting diodes.

Chapter 1, Volume 2, “Diagnosis of Electrical Machines by External Field Measurement”, by R. Pusca, E. Lefevre, D. Mercier, R. Romary and M. Irhoumah, presents a diagnostic method that exploits the information delivered by external flux sensors placed in the vicinity of rotating electrical machines in order to detect a stator inter-turn short circuit. The external magnetic field measured by the flux sensors originates from the airgap flux density and from the end winding currents, attenuated by the magnetic parts of the machine. In the faulty case, an internal magnetic dissymmetry occurs, which can be found again in the external magnetic field. Sensitive harmonics are extracted from the signals delivered by a pair of flux sensors placed at 180° from each other around the machine, and the data obtained for several sensor positions are analyzed by fusion techniques using the belief function theory. The diagnosis method is applied on induction and synchronous machines with artificial stator faults. It is shown that the probability of detecting the fault using the proposed fusion technique on various series of measurements is high.

Chapter 2, Volume 2, “Signal Processing Techniques for Transient Fault Diagnosis”, by J.A. Daviu and R.A.O. Rios, revises the most relevant signal processing tools employed for condition monitoring of electric motors. First, the importance of the predictive maintenance area of the electric motors due to the extensive use of these machines in many industrial applications is pointed out. In this context, the most important predictive maintenance techniques are revised, showing the advantages such as the simplicity, remote monitoring capability and broad fault coverage of motor current analysis methods. In this regard, two basic approaches based on current analysis are explained: the classical methods, relying on the Fourier transform of steady-state current (motor current signature analysis – MCSA), and novel methods based on the analysis of startup currents (advanced transient current signature analysis – ATCSA). In the chapter, the most significant signal processing tools employed for MCSA and ATCSA are explained and revised. For MCSA, the basic problems derived from the application of the Fourier transform as well as other constraints of the methodology are explained. For ATCSA, the most suitable signal processing techniques are described, classifying them into continuous and discrete transforms. One representative of each group is accurately described (the discrete wavelet transform for discrete tools and the Hilbert-Huang transform for continuous tools), accompanying the explanation with illustrative examples. Finally, we discussed several examples of the application of each tool to electric motor fault diagnosis.

Chapter 3, Volume 2, “Accurate Stator Fault Detection in an Induction Motor Using the Symmetrical Current Components”, by M. Bouzid and G. Champenois, deals with the accurate detection of stator faults such as inter-turns short circuit, phase-to-phase and phase-to-ground faults of the induction motor, using the symmetrical current components. The detection method is based on the monitoring of the behavior of the negative and zero sequence stator currents of the machine. This chapter also develops analytical expressions of these components obtained using the coupled inductance model of the machine. However, despite its efficiency, the negative sequence current-based method has its own limitations to detect accurate incipient stator faults in an induction motor. This limit can be explained by the fact that the negative sequence current generated in a faulty motor does represent not only the asymmetry introduced by the fault, but also by other superposed asymmetries, such as the voltage imbalance, the inherent asymmetry in the machine and the inaccuracy of the sensors. This aspect can generate false alarm and make the achievement of accurate incipient stator fault detection very difficult. Thus, to increase the accuracy of the fault detection and the sensitivity of the negative sequence current under different disturbances, this chapter proposes an efficient method able to compensate the effect of the different considered disturbances using experimental techniques having the originality to isolate the negative sequence current of each disturbance. The efficiency of all these proposed methods is validated experimentally on a 1.1-kW motor under different stator faults. Moreover, an original monitoring system, based on neural networks, is also presented and described to automatically detect and diagnose incipient stator faults.

Chapter 4, Volume 2, “Bearing Fault Diagnosis in Rotating Machines”, by C. Delpha, D. Diallo, J. Harmouche, M. Benbouzid, Y. Amirat and E. Elbouchikhi, is focused on detection, estimation and diagnosis of mechanical faults in electrical machines. Nowadays, it is necessary to rapidly assess the structural health of a system without disassembling its elements. For this insitu diagnosis purpose, the use of experimental data is very imperative. Moreover, the monitoring and maintenance costs must be reduced while ensuring satisfactory security performances. In this chapter, we focus on vibration-based signals combined with statistical techniques for bearing fault evaluation. Based on a four-step diagnosis process (modeling, preprocessing, feature extraction and feature analysis), the combination of several techniques such as principal components analysis and linear discriminant analysis in a global approach is explored to monitor the condition of vibration-based bearings. The main advantage of this approach is that prior knowledge on the bearing characteristics is not required. A particularly reduced frequency analysis has led to efficiently differentiate the bearing fault types and evaluate the bearing fault severities.

Chapter 5, Volume 2, “Diagnosis and Prognosis of Proton Exchange Membrane Fuel Cells”, by Z. Li, Z. Zheng and F. Gao, deals with the diagnostic and prognostic issues of fuel cell systems, especially the proton exchange membrane (PEMFC) type. First, the basic functioning principle of PEMFCs and their current development and application status are presented. Their high cost, low reliability and durability make them unfit for commercialization. In the following sections, degradation mechanisms related to both the aging effect and the system operations are analyzed. In addition, typical variables and characterization tools, such as polarization curve, electrochemical impedance spectroscopy, linear sweep voltammetry and cyclic voltammetry, are introduced for the evaluation of PEMFC degradation. Various diagnostic and prognostic methods in the literature are further classified based on their input-to-output process model of the system, namely model-based, data-driven and hybrid methods. Finally, two case studies for diagnosis and prognosis are given at the end of each part to give the readers a general and clearer illustration of these two issues.

Introduction written by Abdenour SOUALHI and Hubert RAZIK.

1Diagnostic Methods for the Health Monitoring of Gearboxes

1.1. Introduction

Maintaining the safety and availability of electromechanical systems (machines) while minimizing operating costs is one of the major challenges industry faces today. To achieve this, machinery health monitoring becomes a necessity. The choice of monitoring techniques depends on the nature of installation and potential degradation. These are usually processes that can either be performed during operation (e.g., monitoring temperature) or delayed (e.g., lubricant analysis), thus requiring scheduled shutdowns of the machines. Moreover, upon diagnosis and depending on the reliability level of the machine operation, a maintenance process can be implemented. The first form of maintenance is called “corrective maintenance.” This strategy is followed only after the appearance of a failure. This strategy involves sudden and uncontrolled shutdowns. The second form of maintenance is called “preventive maintenance.” This is conducted at predetermined intervals or based on a certain pre-established criterion. Hence, preventive maintenance includes two types of maintenance strategies: systematic and conditional. Systematic preventive maintenance is scheduled periodically without taking into account the machine diagnostic operation, and there is no intervention before a predetermined deadline.

It is based on different criteria, for example, the number of hours of operation or the number of cycles of use. Maintenance operations such as lubrication or oil changes are examples of preventive maintenance. These are not curative interventions but actions, usually simple and inexpensive, seeking to minimize the failure rate. Nevertheless, following the geometry dispersions of components, the heterogeneity of materials used and the possible surcharges of operations, degradation may occur before the scheduled deadline. In addition, a defect does not appear during the expected period of time, leading to the replacement of components in a good condition which in turn leads to added maintenance cost. Thus, conditional preventive maintenance must be adopted when reliability is the key factor. This strategy is based on features characterizing the health status of the machine to predict and diagnose the appearance of possible failures before they reach the stage causing the breakdown of the machine. Hence, this chapter details and contextualizes the diagnosis of gears. It also presents failures that appear in gearboxes comprising gears and their types. Then, it introduces analysis methods that are generally used, followed by the presentation of main monitoring tools. Finally, we present the state-of-the-art of various techniques for diagnosing gear defects.

1.2. Identification of critical components in gearboxes

Figure 1.1 shows a gearbox with a set of interconnected mechanical components integrated within a housing. The gearbox mainly comprises a gear train that performs the reduction of motion connected to an electric motor that acts as a power generator. Bearings are also part of the gearbox, to guide rotation. They are connected to rotating shafts, thus serving as a supporting structure for the gearbox. Finally, the last elements of the gearbox are the driven mechanisms, including the couplings that ensure transmission of torque, mechanical load output or brakes that allow the slowing down, or even immobilization, of the movement of the assembly. All of the aforementioned elements have influence on the dynamic behavior of the gearbox, but it is generally accepted that the gear train is one of the main sources of excitation, and gears also respond very well to the specific performance, efficiency and power requirements imposed by modern standards. However, conditions such as comfort, vibratory behavior and reliability impose new technological and economic pressure on this component. At the same time, bearings are also subjected to relatively important functional constraints.

Figure 1.2 shows the results of various researches studying origins of faults and their location in a power transmission-based gearbox and also demonstrate that gears are the most sensitive component [BRE 02]. Bearings come in second. Thus, in addition to manufacturing and/or assembly defects, there are numerous causes that lead to damage and hence give rise to anomalies with several degrees of severity. So, from both industrial and scientific points of view, it is important to focus gearbox diagnostic efforts primarily on gears and secondarily on bearings.

Figure 1.1.Example kinematic diagram of a gearbox

Figure 1.2.Fault distribution in gearbox transmissions. For a color version of thefigures in this book, see www.iste.co.uk/soualhi/electrical1.zip

1.2.1. Types of gears