WO2019220470A1 - Calibration and diagnosis device and method for electrical machines - Google Patents

Calibration and diagnosis device and method for electrical machines Download PDF

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Publication number
WO2019220470A1
WO2019220470A1 PCT/IT2018/000073 IT2018000073W WO2019220470A1 WO 2019220470 A1 WO2019220470 A1 WO 2019220470A1 IT 2018000073 W IT2018000073 W IT 2018000073W WO 2019220470 A1 WO2019220470 A1 WO 2019220470A1
Authority
WO
WIPO (PCT)
Prior art keywords
calibration
electrical machine
storage unit
diagnosis device
electrical
Prior art date
Application number
PCT/IT2018/000073
Other languages
French (fr)
Inventor
Denny CHIONO
Davide Bettoni
Fabio BORELLO
Original Assignee
Mavel S.R.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mavel S.R.L. filed Critical Mavel S.R.L.
Priority to CN201880095712.2A priority Critical patent/CN112425060A/en
Priority to PCT/IT2018/000073 priority patent/WO2019220470A1/en
Priority to EP18743095.4A priority patent/EP3794723A1/en
Publication of WO2019220470A1 publication Critical patent/WO2019220470A1/en

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/14—Electronic commutators
    • H02P6/16—Circuit arrangements for detecting position
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
    • G01D5/26—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light
    • G01D5/32—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light
    • G01D5/34—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells
    • G01D5/347—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells using displacement encoding scales
    • G01D5/3473—Circular or rotary encoders
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
    • G01H1/00—Measuring characteristics of vibrations in solids by using direct conduction to the detector

Definitions

  • the present invention refers to a device and a method for calibrating and diagnosing electrical machines, in particular synchronous reluctance electrical machines.
  • the invention refers to a device for calibrating and diagnosing electrical motors, preferably synchronous reluctance motors assisted by permanent magnets, adapted to be installed on the motor to allow performing its optimum driving by an inverter connected thereto, and have a diagnostic situation of the motor during its operation.
  • a control parameter of synchronous reluctance motors assisted by permanent magnets, used by the inverter, is the instantaneous angular position of the rotor magnetic poles.
  • a calibration operation is performed to correct the error between the detected rotor position, for example by a position sensor, and the instantaneous rotor angular position, in particular the instantaneous angular position of the magnetic poles of the rotor.
  • This calibration operation is performed upon coupling the inverter with the motor, before its installation, and the calibration data are stored in an inverter memory, to correct the mechanical error through an offset software; the stored calibration data are afterwards used for optimally driving the motor coupled thereto.
  • Object of the present invention is solving the above prior art problems, by providing a device for calibrating and diagnosing electrical machines, adapted to be installed on the electrical machine, which allows performing its optimum driving, both during its first installation and during possible repairs and/or replacements thereof; another object of the invention is having a diagnostic situation of the machine during its operation; a further object is knowing the origin, in every instant of the machine life, of every major component thereof.
  • Figure 1 shows a perspective view of a component of the device for calibrating and diagnosing synchronous reluctance electrical machines according to the invention.
  • Figure 2 shows a block diagram of the device for calibrating and diagnosing synchronous reluctance electrical machines according to the invention.
  • the calibration and diagnosis device 10 for electrical machines of the invention comprises: a position sensor 11 configured for being connected to a rotor of an electrical machine and adapted to measure the angular position of the rotor; a storage unit 14 in which data computed during the production of the electrical machine are stored and can be used for correcting errors between the rotor position detected by the position sensor 11 and the actual angular rotor position, as will be described below in more detail; and a microprocessor 15 connected to the position sensor 11 and to the storage unit 14 and adapted to store, in the storage unit 14, information detected by the position sensor 11, to manage and process information stored in the storage unit 14 and/or detected by the position sensor 11 and to communicate the processed data to an inverter 20 connected to the electrical machine through analogue 21 and/or digital communication lines 22, for example a communication can bus.
  • the calibration and diagnosis device 10 for electrical machines of the invention further comprises at least one vibration sensor 12, for example comprising accelerometers of the MEMS type, adapted to detect vibration values of the electrical machine during its operation, said microprocessor 15 being further connected to the vibration sensor 12 and adapted to manage and process information detected by the vibration sensor 12, to store them in the storage unit 14 and to communicate the processed data to the inverter 20 through the analogue 21 and/or digital communication lines 22 to provide a diagnostic situation of the electrical machine during its operation.
  • vibration sensor 12 for example comprising accelerometers of the MEMS type, adapted to detect vibration values of the electrical machine during its operation
  • said microprocessor 15 being further connected to the vibration sensor 12 and adapted to manage and process information detected by the vibration sensor 12, to store them in the storage unit 14 and to communicate the processed data to the inverter 20 through the analogue 21 and/or digital communication lines 22 to provide a diagnostic situation of the electrical machine during its operation.
  • data related to origin for example, manufacturing date/batch, identification number and supplier
  • major component thereof for example, copper wire, magnets, stator and rotor packs, shaft, structures, etc.
  • the electrical machine is a synchronous reluctance electrical motor assisted by permanent magnets.
  • the position sensor 11 is a magnetic sensor comprising: a rotary element 16 connected to the rotor of the electrical machine and comprising a magnet; a fixed element 18, preferably comprising a plurality of hall -effect magnetic sensors of a known type.
  • the calibration and diagnosis device 10 for electrical machines of the invention is adapted to be installed on the electrical machine, preferably on the synchronous reluctance electrical motor assisted by permanent magnets and preferably comprises a case inside which sensors 11, 12, storage unit 14 and microprocessor 15 are contained .
  • the angular rotor position is measured; such data are compared with the value measured by the position sensor 11 of the device 10 of the invention to detect its error; the error value is then stored by the microprocessor 15 into the storage unit 14.
  • the measure of the angular rotor position performed when producing the electrical machine comprises a step of mechanically pre aligning between the sensor magnet and a rotor magnet, followed by a step in which the electrical machine is actuated, thereby rotating the rotor, a following step of turning the electrical machine off, and a following step in which the machine is left rotate idle.
  • the value of the angle of the magnetic field of the rotor is obtained by measuring the phase voltages of the machine, which are in phase with the magnetic flow.
  • the vibration sensor 12 detects the machine vibrations at certain time intervals, and such data are stored by the microprocessor 15 into the storage unit 14.
  • Data stored into the storage unit 14 are saved and processed by the microprocessor 15, and communicated to the inverter 20, for example through the analogue 21 and/or the digital communication lines 22, to drive the electrical machine, in particular the motor, using the actual value of the angular position of the rotor and to perform a diagnosis of the degrade of the motor in time .
  • the inverter 20 performs the diagnosis of the degrade of the electrical machine in time by processing data detected by the vibration sensor 12 supplied by the microprocessor 15 to the inverter 20, together with other data available to the inverter 20 (rotation speed, torque) .
  • data detected by the vibration sensor 12 supplied by the microprocessor 15 to the inverter 20, together with other data available to the inverter 20 (rotation speed, torque) .
  • the inverter stores on the device 10 of the electrical machine the measured vibrations value.
  • the inverter is able to establish the degrade condition of the electrical machine.
  • These data stored in the storage unit 14 deal for example with: magnetic rotor angle, serial number and type of motor, serial/batch number, manufacturing date, value of motor performances in time to measure its degrade caused by the increase of the vibrations, comparing data detected by the vibration sensor 12, stored into the storage unit 14 by the microprocessor 15 during the motor life.
  • the calibration and diagnosis device 10 for electrical machines of the invention allows a better representation of the magnetic pole of the rotor through the correction of the mechanical error through an offset software stored in the device memory.
  • the calibration and diagnosis device 10 for electrical machines of the invention allows having a forecast of the machine life by processing the vibration levels, and knowing the origin, at any time during the electrical machine life, of every major component thereof.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)

Abstract

A calibration and diagnosis device (10) for electrical machines is described, comprising a position sensor (11) interfaced to a rotor of an electrical machine to measure the angular position of the rotor, a storage unit (14) in which is data computed during the production of the electrical machine are stored, and can be used for correcting errors between the detected rotor position and the actual angular rotor position, a microprocessor (15) adapted to store into the storage unit (14) information detected by the position sensor (11), to manage and process information stored in the storage unit (14) and/or detected by the position sensor (11) and to communicate the processed data to an inverter (20) connected to the electrical machine to drive the electrical machine using the actual value of the angular rotor position; an operating method for such device (10) is further described.

Description

CALIBRATION AND DIAGNOSIS DEVICE AND METHOD FOR ELECTRICAL MACHINES
The present invention refers to a device and a method for calibrating and diagnosing electrical machines, in particular synchronous reluctance electrical machines.
More in particular, the invention refers to a device for calibrating and diagnosing electrical motors, preferably synchronous reluctance motors assisted by permanent magnets, adapted to be installed on the motor to allow performing its optimum driving by an inverter connected thereto, and have a diagnostic situation of the motor during its operation.
Electrical machines, in particular electrical motors, are known, and the use of inverters connected to the motors for controlling their operation is known.
A control parameter of synchronous reluctance motors assisted by permanent magnets, used by the inverter, is the instantaneous angular position of the rotor magnetic poles.
In known motors, upon firstly installing the motor and its coupling with the inverter, a calibration operation is performed to correct the error between the detected rotor position, for example by a position sensor, and the instantaneous rotor angular position, in particular the instantaneous angular position of the magnetic poles of the rotor.
This calibration operation is performed upon coupling the inverter with the motor, before its installation, and the calibration data are stored in an inverter memory, to correct the mechanical error through an offset software; the stored calibration data are afterwards used for optimally driving the motor coupled thereto.
These known electrical motors have the problem that, every time it is necessary to repair and/or replace the motor, it is necessary to repeat the calibration operation of the inverter associated with the motor, which cannot be performed simply in the place where the motor is installed, but must be performed in a suitably fitted workshop.
No electrical motors are known, which allow having a diagnostic situation of the motor during its operation, in every instant of its life, with information about every major component of the motor .
Object of the present invention is solving the above prior art problems, by providing a device for calibrating and diagnosing electrical machines, adapted to be installed on the electrical machine, which allows performing its optimum driving, both during its first installation and during possible repairs and/or replacements thereof; another object of the invention is having a diagnostic situation of the machine during its operation; a further object is knowing the origin, in every instant of the machine life, of every major component thereof.
The above and other objects and advantages of the invention, as will appear from the following description, are obtained with a calibration and diagnosis device and method for electrical machines as claimed in the respective independent claims. Preferred embodiments and non-trivial variations of the present invention are the subject matter of the dependent claims.
It is intended that all enclosed claims are an integral part of the present description.
It will be immediately obvious that numerous variations and modifications (for example related to shape, sizes, arrangements and parts with equivalent functionality) can be made to what is described, without departing from the scope of the invention as appears from the enclosed claims.
The present invention will be better described by some preferred embodiments thereof, provided as a non-limiting example, with reference to the enclosed drawings, in which:
Figure 1 shows a perspective view of a component of the device for calibrating and diagnosing synchronous reluctance electrical machines according to the invention; and
Figure 2 shows a block diagram of the device for calibrating and diagnosing synchronous reluctance electrical machines according to the invention.
With reference to the Figures, the calibration and diagnosis device 10 for electrical machines of the invention comprises: a position sensor 11 configured for being connected to a rotor of an electrical machine and adapted to measure the angular position of the rotor; a storage unit 14 in which data computed during the production of the electrical machine are stored and can be used for correcting errors between the rotor position detected by the position sensor 11 and the actual angular rotor position, as will be described below in more detail; and a microprocessor 15 connected to the position sensor 11 and to the storage unit 14 and adapted to store, in the storage unit 14, information detected by the position sensor 11, to manage and process information stored in the storage unit 14 and/or detected by the position sensor 11 and to communicate the processed data to an inverter 20 connected to the electrical machine through analogue 21 and/or digital communication lines 22, for example a communication can bus.
Preferably, the calibration and diagnosis device 10 for electrical machines of the invention further comprises at least one vibration sensor 12, for example comprising accelerometers of the MEMS type, adapted to detect vibration values of the electrical machine during its operation, said microprocessor 15 being further connected to the vibration sensor 12 and adapted to manage and process information detected by the vibration sensor 12, to store them in the storage unit 14 and to communicate the processed data to the inverter 20 through the analogue 21 and/or digital communication lines 22 to provide a diagnostic situation of the electrical machine during its operation.
In the storage unit 14, in addition to information related to sensors 11, 12, data related to origin (for example, manufacturing date/batch, identification number and supplier) at any time of the life of the electrical machine about every major component thereof (for example, copper wire, magnets, stator and rotor packs, shaft, structures, etc.) are stored.
In a preferred way, the electrical machine is a synchronous reluctance electrical motor assisted by permanent magnets.
Preferably, the position sensor 11 is a magnetic sensor comprising: a rotary element 16 connected to the rotor of the electrical machine and comprising a magnet; a fixed element 18, preferably comprising a plurality of hall -effect magnetic sensors of a known type.
The calibration and diagnosis device 10 for electrical machines of the invention is adapted to be installed on the electrical machine, preferably on the synchronous reluctance electrical motor assisted by permanent magnets and preferably comprises a case inside which sensors 11, 12, storage unit 14 and microprocessor 15 are contained .
In its operation, when producing the electrical machine, preferably a synchronous reluctance electrical motor assisted by permanent magnets, the angular rotor position is measured; such data are compared with the value measured by the position sensor 11 of the device 10 of the invention to detect its error; the error value is then stored by the microprocessor 15 into the storage unit 14.
Preferably, the measure of the angular rotor position performed when producing the electrical machine, comprises a step of mechanically pre aligning between the sensor magnet and a rotor magnet, followed by a step in which the electrical machine is actuated, thereby rotating the rotor, a following step of turning the electrical machine off, and a following step in which the machine is left rotate idle.
In this step of idly rotating the machine, the value of the angle of the magnetic field of the rotor is obtained by measuring the phase voltages of the machine, which are in phase with the magnetic flow.
These measures are performed when producing the electrical machine using an inverter connected to the electrical machine; once the error value has been stored by the microprocessor 15 into the storage unit 14, the electrical machine can be coupled with any inverter without having to repeat the calibration operation.
During the operation of the electrical machine, the vibration sensor 12 detects the machine vibrations at certain time intervals, and such data are stored by the microprocessor 15 into the storage unit 14.
Data stored into the storage unit 14 are saved and processed by the microprocessor 15, and communicated to the inverter 20, for example through the analogue 21 and/or the digital communication lines 22, to drive the electrical machine, in particular the motor, using the actual value of the angular position of the rotor and to perform a diagnosis of the degrade of the motor in time .
In a preferred way, the inverter 20 performs the diagnosis of the degrade of the electrical machine in time by processing data detected by the vibration sensor 12 supplied by the microprocessor 15 to the inverter 20, together with other data available to the inverter 20 (rotation speed, torque) . In particular, in order to be able to use information about motor vibrations to track a life profile of the electrical machine, it is necessary to be able to refer the measure detected by the vibration sensor 12 to a certain stable operating point of the electrical machine (torque/speed) , which the inverter has available. Preferably, at regular intervals (every N hours of operation) , the inverter stores on the device 10 of the electrical machine the measured vibrations value.
Through the knowledge of data related to the electrical machine and the analysis of vibrations detected as function of time, the inverter is able to establish the degrade condition of the electrical machine.
These data stored in the storage unit 14 deal for example with: magnetic rotor angle, serial number and type of motor, serial/batch number, manufacturing date, value of motor performances in time to measure its degrade caused by the increase of the vibrations, comparing data detected by the vibration sensor 12, stored into the storage unit 14 by the microprocessor 15 during the motor life.
Advantageously, the calibration and diagnosis device 10 for electrical machines of the invention allows a better representation of the magnetic pole of the rotor through the correction of the mechanical error through an offset software stored in the device memory.
Moreover, the calibration and diagnosis device 10 for electrical machines of the invention allows having a forecast of the machine life by processing the vibration levels, and knowing the origin, at any time during the electrical machine life, of every major component thereof.

Claims

1. Calibration and diagnosis device (10) for electrical machines comprising:
a position sensor (11) configured for being connected to a rotor of an electrical machine and adapted to measure the angular position of the rotor;
a storage unit (14) in which data computed during the production of the electrical machine are stored, and are used for correcting errors between the rotor position detected by the position sensor (11) and the actual angular rotor position;
a microprocessor (15) connected to the position sensor (11) and to the storage unit (14) and adapted to store into the storage unit (14) information detected by the position sensor (11) , to manage and process information stored in the storage unit (14) and/or detected by the position sensor (11) and to communicate the processed data to an inverter (20) connected to the electrical machine through analogue (21) and/or digital communication lines (22) , to drive the electrical machine using the actual value of the angular rotor position.
2. Calibration and diagnosis device (10) for electrical machines according to claim 1, characterized in that it further comprises at least one vibration sensor (12) adapted to detect vibration values of the electrical machine during its operation, and in that said microprocessor (15) is further connected to the vibration sensor (12) and adapted to manage and process information detected by the vibration sensor (12) , to store them into the storage unit (14) and to communicate the processed data to the inverter (20) through the analogue (21) and/or digital communication lines (22) to perform a diagnosis of the degrade of the motor in time.
3. Calibration and diagnosis device (10) for electrical machines according to claim 2, characterized in that the vibration sensor (12) comprises accelerometers.
4. Calibration and diagnosis device (10) for electrical machines according to any one of the previous claims, characterized in that the electrical machine is an electrical motor.
5. Calibration and diagnosis device (10) for electrical machines according to any one of the previous claims, characterized in that the position sensor (11) is a magnetic sensor comprising a rotary element (16) connected to the rotor of the electrical machine and comprising a magnet, and a fixed element (18) comprising a plurality of magnetic sensors.
6. Calibration and diagnosis device (10) for electrical machines according to any one of the previous claims, characterized in that it is configured to be installed on the electrical machine and comprises a case inside which sensors (11, 12) , storage unit (14) and microprocessor (15) are stored.
7. Calibration and diagnosis device (10) for electrical machines according to any one of the previous claims, characterized in that in the storage unit (14) , in addition to information related to sensors (11, 12) , data related to an origin, at any time during the life of the electrical machine, of every major component thereof are stored.
8. Operating method of a calibration and diagnosis device (10) for electrical machines according to any one of the previous claims, characterized in that comprises a step of producing the electrical machine in which the angular rotor position is measured, and measured data are compared with a value measured by the position sensor (11) of the device (10) to detect the error, and a step in which the error value is stored by the microprocessor (15) into the storage unit (14) .
9. Operating method of a calibration and diagnosis device (10) for electrical machines according to claim 8, characterized in that it comprises a step in which the vibration sensor (12) detects the machine vibrations at certain time intervals, and such data are stored by the microprocessor (15) into the storage unit (14) .
10. Operating method of a calibration and diagnosis device (10) for electrical machines according to claim 8 or 9, characterized in that data stored in the storage unit (14) are saved and processed by the microprocessor (15) , and communicated to the inverter (20) through the analogue (21) and/or digital communication lines (22), to drive the electrical machine using the actual value of the angular rotor position and to perform a diagnosis of the motor degrade in time.
11. Electrical machine characterized in that it comprises a calibration and diagnosis device (10) for electrical machines according to any one of claims 1 to 7.
PCT/IT2018/000073 2018-05-18 2018-05-18 Calibration and diagnosis device and method for electrical machines WO2019220470A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
CN201880095712.2A CN112425060A (en) 2018-05-18 2018-05-18 Calibration and diagnostic apparatus and method for electrical machines
PCT/IT2018/000073 WO2019220470A1 (en) 2018-05-18 2018-05-18 Calibration and diagnosis device and method for electrical machines
EP18743095.4A EP3794723A1 (en) 2018-05-18 2018-05-18 Calibration and diagnosis device and method for electrical machines

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IT2018/000073 WO2019220470A1 (en) 2018-05-18 2018-05-18 Calibration and diagnosis device and method for electrical machines

Publications (1)

Publication Number Publication Date
WO2019220470A1 true WO2019220470A1 (en) 2019-11-21

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EP (1) EP3794723A1 (en)
CN (1) CN112425060A (en)
WO (1) WO2019220470A1 (en)

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EP2675059A1 (en) * 2012-06-15 2013-12-18 SICK STEGMANN GmbH Drive system
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CN112425060A (en) 2021-02-26
EP3794723A1 (en) 2021-03-24

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