A review of sensorless control in induction machines using HF injection and test vectors

This paper describes various methods aimed at tracking the flux and rotor position for cage induction machines without a shaft sensor using specially designed saliencies or natural saliencies. The estimation methods employ a High Frequency (HF) signal or test vectors to detect the machine saliency. As is common knowledge, multiple saliences can cause problems to track only one particular saliency. Ways to overcome this problem for rotor position and rotor flux tracking are discussed. The performance of these methods is investigated at all loads at low and zero speed and also at zero fundamental frequency.peer-reviewe

Assessment of torque components in brushless permanent-magnet machines through numerical analysis of the electromagnetic field

For the calculation of torque in brushless (BL) alternating current motors a local method is proposed, based on the Maxwell stress theory and the filtered contributions due to the harmonics of the magnetic vector potential in the motor air gap. By considering the space fundamental field only, the method can efficiently estimate the average synchronous torque for a variety or motor topologies, including concentrated winding designs. For BL direct current motor analysis a global method is introduced, based on the virtual work principle expressed in terms of energy components in various motor regions. The method leads to simplifications in the average torque calculation and enables the direct identification of the cogging and ripple components. The mathematical procedures have been validated against experiments and other numerical techniques

Detection of inter-turn faults in multi-phase ferrite-PM assisted synchronous reluctance machine

Inter-turn winding faults in five-phase ferrite-permanent magnet-assisted synchronous reluctance motors (fPMa-SynRMs) can lead to catastrophic consequences if not detected in a timely manner, since they can quickly progress into more severe short-circuit faults, such as coil-to-coil, phase-to-ground or phase-to-phase faults. This paper analyzes the feasibility of detecting such harmful faults in their early stage, with only one short-circuited turn, since there is a lack of works related to this topic in multi-phase fPMa-SynRMs. Two methods are tested for this purpose, the analysis of the spectral content of the zero-sequence voltage component (ZSVC) and the analysis of the stator current spectra, also known as motor current signature analysis (MCSA), which is a well-known fault diagnosis method. This paper compares the performance and sensitivity of both methods under different operating conditions. It is proven that inter-turn faults can be detected in the early stage, with the ZSVC providing more sensitivity than the MCSA method. It is also proven that the working conditions have little effect on the sensitivity of both methods. To conclude, this paper proposes two inter-turn fault indicators and the threshold values to detect such faults in the early stage, which are calculated from the spectral information of the ZSVC and the line currentsPeer ReviewedPostprint (published version

A review of sensorless control in induction machines using HF injection, test vectors and PWM harmonics

This paper gives a review of sensorless methods developed for ac drives’ operation at very low and zero speed. The sensorless drives presented in this paper use reluctance spatial anisotropy to track the mechanical rotor position, allowing the use of vector control. To extract the position information additional test signals in form of active vector pulses or continuous high frequency signals are injected into the machine. This paper also presents a technique which does not make use of additional test signals, but only components resulting from the inverter PWM pattern. Practical results show that with all reviewed methods sensorless vector control at very low and zero speed is possible. However, disturbances (eg. coming from the inverter or magnetic saturation) affect the position signal significantly and require appropriate compensation.peer-reviewe

Direct torque control of brushless DC drives with reduced torque ripple

The application of direct torque control (DTC) to brushless ac drives has been investigated extensively. This paper describes its application to brushless dc drives, and highlights the essential differences in its implementation, as regards torque estimation and the representation of the inverter voltage space vectors. Simulated and experimental results are presented, and it is shown that, compared with conventional current control, DTC results in reduced torque ripple and a faster dynamic response

A precise, General, Non-Invasive and Automatic Speed Estimation Method for MCSA Steady-State Diagnosis and Efficiency Estimation of Induction Motors in the 4.0 Industry

Tesis por compendio[ES] Hay dos aspectos cruciales a la hora de operar motores de inducción en la industria: la estimación de su eficiencia (para minimizar el consumo de energía) y su diagnóstico (para evitar paradas intempestivas y reducir los costes de mantenimiento). Para estimar la eficiencia del motor es necesario medir tensiones y corrientes. Por ello, resulta conveniente y muy útil utilizar la misma corriente para diagnosticar también el motor (Motor Current Signature Analysis: MCSA). En este sentido, la técnica MCSA más adecuada es aquella basada en la localización de armónicos de fallo en el espectro de la corriente de línea del estator en régimen permanente, pues esta es la condición de funcionamiento de la mayoría de los motores de inducción de la industria. Por otro lado, dado que la frecuencia de estos armónicos depende de la velocidad, resulta imprescindible conocer esta magnitud con precisión, ya que esto permite localizar correctamente los armónicos de fallo, y, por tanto, reducir las posibilidades de falsos positivos/negativos. A su vez, una medida precisa de la velocidad también permite calcular con precisión la potencia mecánica, lo que se traduce en una estimación más exacta del rendimiento. Por último, para adaptarse a las necesidades de la Industria 4.0, en la que se monitoriza continuamente un gran número de motores, la velocidad también debe ser obtenida de manera no invasiva, automática y para cualquier motor de inducción. A este respecto, dado que la medición precisa de la velocidad a través de un encóder es invasiva y costosa, las técnicas de estimación de velocidad sin sensores (SSE en inglés) se convierten en la mejor opción. En la primera parte de esta tesis se realiza un análisis exhaustivo de las familias de técnicas SSE presentes en la literatura técnica. Como se demuestra en ella, aquellos métodos basados en armónicos de ranura (RSHs en inglés) y en armónicos laterales de frecuencia rotacional (RFSHs) son potencialmente los únicos que pueden satisfacer todos los requisitos mencionados anteriormente. Sin embargo, como también se demuestra en esta parte, y hasta esta tesis, siempre había existido un compromiso entre la precisión (característica de los RSHs) y la aplicabilidad general del método (característica de los RFSHs). En la segunda parte, y núcleo de esta tesis, se presenta una metodología que acaba con este compromiso, proporcionando así el primer método de estimación de velocidad preciso, general, no invasivo y automático para el diagnóstico en estado estacionario MCSA y la estimación de la eficiencia de motores de inducción que operan en un contexto de Industria 4.0. Esto se consigue desarrollando una novedosa técnica basada en RSHs que, por primera vez en la literatura técnica, elimina la necesidad de conocer/estimar el número de ranuras del rotor, lo que había impedido hasta la fecha que estos métodos fueran de aplicación general. Esta técnica proporciona además un procedimiento fiable y automático para localizar la familia de RSHs en el espectro de la corriente de línea de un motor de inducción. De igual forma y sin la ayuda de un experto, la técnica es capaz de determinar los parámetros necesarios para estimar la velocidad a partir de los RSHs, utilizando medidas tomadas en régimen estacionario. La metodología es validada utilizando motores con diferentes características y tipos de alimentaciones, empleando para ello simulaciones, pruebas de laboratorio y 105 motores industriales. Además, se muestra un caso de aplicación industrial en el que el algoritmo desarrollado se implementa en un sistema de monitorización continua mediante MCSA, lo que acaba conduciendo al descubrimiento de un nuevo fallo en motores sumergibles de pozo profundo: el desgaste de los anillos de cortocircuito. Por último, se presenta una segunda aplicación directa para este tipo de motores derivada del procedimiento de detección de RSHs: el uso de estos armónicos para diagnosticar, en fase temprana, cortocircuitos entre espiras.[CA] Hi ha dos aspectes crucials a l'hora d'operar motors d'inducció en la indústria: l'estimació de la seua eficiència (per a minimitzar el consum d'energia) i el seu diagnòstic (per a evitar parades intempestives i reduir els costos de manteniment). Per a estimar l'eficiència del motor és necessari mesurar tensions i corrents. Per això, resulta convenient i molt útil utilitzar el mateix corrent per a diagnosticar també el motor (Motor Current Signature Analysis: MCSA). En aquest sentit, la tècnica MCSA més adequada és aquella basada en la localització d'harmònics de fallada en l'espectre del corrent de línia de l'estator en règim permanent, ja que aquesta és la condició de funcionament de la majoria dels motors d'inducció de la indústria. D'altra banda, atés que la freqüència d'aquests harmònics depén de la velocitat, resulta imprescindible conéixer aquesta magnitud amb precisió, ja que això permet localitzar correctament els harmònics de fallada i, per tant, reduir les possibilitats de falsos positius/negatius. Al seu torn, una mesura precisa de la velocitat també permet calcular amb precisió la potència mecànica, la qual cosa es tradueix en una estimació més exacta del rendiment. Finalment, per a adaptar-se a les necessitats de la Indústria 4.0, en la qual es monitora contínuament un gran nombre de motors, la velocitat també ha de ser obtinguda de manera no invasiva, automàtica i per a qualsevol motor d'inducció. En aquest sentit, atès que el mesurament precís de la velocitat a través d'un encóder és invasiva i costosa, les tècniques d'estimació de velocitat sense sensors (SSE en anglés) es converteixen en la millor opció. En la primera part d'aquesta tesi es realitza una anàlisi exhaustiva de totes les famílies de tècniques SSE presents en la literatura tècnica. Com es demostra en ella, aquells mètodes basats en harmònics de ranura (RSHs en anglès) i harmònics laterals de freqüència rotacional (RFSHs en anglés) són els més prometedors, ja que son potencialment els únics que poden satisfer tots els requisits esmentats anteriorment. No obstant això, com també es demostra en aquesta part, i fins a aquesta tesi, sempre havia existit un compromís entre la precisió (característica dels RSHs) i l'aplicabilitat general del mètode (característica dels RFSHs). En la segona part, i nucli d'aquesta tesi, es presenta una metodologia que acaba amb aquest compromís, proporcionant així el primer mètode d'estimació de velocitat precís, general, no invasiu i automàtic per al diagnòstic en estat estacionari MCSA i l'estimació de l'eficiència de motors d'inducció que operen en un context d'Indústria 4.0. Això s'aconsegueix desenvolupant una nova tècnica basada en RSHs que, per primera vegada en la literatura tècnica, elimina la necessitat de conéixer/estimar el nombre de ranures del rotor, cosa que havia impedit fins avui que aquests mètodes foren d'aplicació general. Aquesta tècnica proporciona a més un procediment fiable i automàtic per a localitzar la família de RSHs en l'espectre del corrent de línia d'un motor d'inducció. De la mateixa forma i sense l'ajuda d'un expert, la tècnica és capaç de determinar els paràmetres necessaris per a estimar la velocitat a partir dels RSHs, utilitzant mesures preses en règim estacionari. La metodologia és validada utilitzant motors amb diferents característiques i condicions d'alimentació, emprant per a això simulacions, proves de laboratori i 105 motors industrials. A més, es mostra un cas real d'aplicació industrial en el qual l'algoritme desenvolupat és implementat en un sistema de monitoratge continu mitjançant MCSA, la qual cosa acaba conduint al descobriment d'una nova fallada en motors submergibles de pou profund: el desgast dels anells de curtcircuit. Finalment, es presenta una segona aplicació directa per a aquest tipus de motors derivada del procediment de detecció de RSHs: l'ús d'aquests harmònics per a diagnosticar, en fase primerenca, curtcircuits entre espires.[EN] There are two crucial aspects when operating induction motors in industry: efficiency estimation (to minimize energy consumption) and diagnosis (to avoid untimely outages and reduce maintenance costs). To estimate the motor's efficiency, it is necessary to measure voltages and currents. Hence, it is convenient and very useful using the same current to also diagnose the motor (Motor Current Signature Analysis: MCSA). In this regard, the most suitable MCSA technique is that based on locating fault harmonics in the spectrum of the stator line current under steady-state, as this is the operating condition of most induction motors in industry. Since the frequency of these harmonics depends on the speed, it becomes essential to be able to know this magnitude with precision, as this makes it possible to correctly locate the fault harmonics, and therefore, reduce the chances of false positives/negatives. In turn, an accurate speed information also allows to calculate the mechanical power with precision, which results in a more accurate estimation of the motor performance. Finally, to adapt to the needs of 4.0 Industry, where large numbers of motors are continuously monitored, the speed must not only be obtained very accurately, but also non-invasively, automatically (without the need for an expert) and for any induction motor. In this regard, since precise speed measurement through a shaft sensor is invasive and expensive, Sensorless Speed Estimation (SSE) techniques become the best option. The first part of this thesis conducts a thorough analysis of all the families of SSE techniques present in the technical literature. As demonstrated therein, those techniques based on Slotting and Rotational Frequency Sideband Harmonics are the most promising, as they can potentially meet all the aforementioned requirements. However, as also proved in this part, and up to this thesis, there had always been a trade-off between accuracy, characteristic of Rotor Slot Harmonics (RSHs), and general applicability, characteristic of Rotational Frequency Sideband Harmonics (RFSHs). The second part, and core of this thesis, presents a methodology that ends with this trade-off between accuracy and general applicability, thus providing the first precise, general, noninvasive and automatic speed estimation method for MCSA steady-state diagnosis and efficiency estimation of induction motors that operate in a 4.0 Industry context. This is achieved by developing a novel RSH-based technique that, for the first time in technical literature, eliminates the need to know/estimate the number of rotor slots, which had so far prevented these techniques to be generally applicable. This technique also provides a reliable and automatic procedure to, from among the high number of significant harmonics present in the spectrum of the line current of an induction motor, locate the RSHs family. Also automatically and without the help of an expert, the technique is able to determine the parameters needed to estimate speed from RSHs, using only measurements taken during the motor normal operation at steady-state. The methodology is validated using motors with different characteristics and supply conditions, by simulations, lab tests and with 105 industrial motors. Furthermore, a real industrial case of application is shown as well, where the speed estimation algorithm is implemented in a continuous motor condition monitoring system via MCSA, which eventually leads to the discovery of a new fault in deep-well submersible motors: the wear of end-rings. Finally, a second direct application derived from the reliable and automatic procedure to detect RSHs is presented: the use of these harmonics to diagnose early-stage inter-turn faults in induction motors of deep-well submersible pumps.Bonet Jara, J. (2023). A precise, General, Non-Invasive and Automatic Speed Estimation Method for MCSA Steady-State Diagnosis and Efficiency Estimation of Induction Motors in the 4.0 Industry [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/194269Compendi

A review of saliency-based sensorless control methods for alternating current machines

Operation of model-based sensorless control of Alternating Current machines at low and zero speeds is unreliable and can fail. To overcome the limitations of sensorless control at low speeds, several alternative techniques have been developed to estimate speed and position. These are mainly based on detecting machine saliencies by measuring the response of the current to some form of voltage injection. This paper discusses injection methods, machine saliencies, and techniques used to extract speed and position that are applicable to both induction machines and permanent magnet synchronous motors.peer-reviewe

A Precise, General, Non-Invasive and Automatic Speed Estimation Method for MCSA Diagnosis and Efficiency Estimation of Induction Motors

[EN] Efficiency estimation and diagnosis via MCSA require precise knowledge of speed. In an industrial environment, speed must be obtained with a non-invasive, automatic and general method. Recent studies have shown that Sensorless Speed Estimation techniques based on detecting Rotational Frequency Sideband Harmonics (RFSHs) or Rotor Slot Harmonics (RSHs) are best suited to these purposes. RFSHs-based methods are easier to apply as they only depend on the number of poles. RSHs-based are much more accurate due to their wider bandwidth. Yet, their use is not trivial as they require to identify the RSHs family, assign to each RSH its order of the current harmonic (¿) and determine the number of rotor slots (R), a rarely known parameter. This paper ends with this trade-off between accuracy and applicability by proposing a novel RSHs-based technique that, for the first time in technical literature, eliminates the need to estimate the number of rotor slots and provides a reliable and automatic procedure to locate the RSHs family and determine their ¿ indices. Finally, the method is validated under all types of conditions and motor designs, by simulations, lab tests and with 105 industrial motors, highlighting its high accuracy (errors below 0.05 rpm), and applicability.This work was supported by the Universitat Politecnica de Valencia and the Spanish Ministry of Science, Innovation and Universities [FPU19/02698]Bonet-Jara, J.; Pons Llinares, J. (2023). A Precise, General, Non-Invasive and Automatic Speed Estimation Method for MCSA Diagnosis and Efficiency Estimation of Induction Motors. IEEE Transactions on Energy Conversion. 38(2):1257-1267. https://doi.org/10.1109/TEC.2022.32208531257126738

General Torque Enhancement Approach for a Nine-Phase Surface PMSM with Built-in Fault Tolerance

The paper investigates maximum possible torque improvement in a two-pole surface permanent magnet synchronous machine (PMSM) with a reduced magnet span, which causes production of highly non-sinusoidal back-EMF. It contains a high third and fifth harmonics, which can be used for the torque enhancement, using stator current harmonic injection. Optimal magnet span is studied first and it is shown that with such a value the machine would be able to develop an insignificantly lower maximum torque than with the full magnet span. Next, field-oriented control (FOC) algorithm, which considers all non-fundamental EMF components lower than the machine phase number, is devised. Using maximum-torque per Ampere (MTPA) principles, optimal ratios between fundamental and all other injected components are calculated and then used in the drive control. The output torque can be in this way increased up to 45% with respect to the one obtainable with fundamental current only. Alternatively, for the same load torque, stator current RMS value can be reduced by 45%. Last but not least, a method for position sensor fault mitigation is introduced. It is based on the alternative use of a back-EMF harmonic for rotor position estimation, instead of the torque enhancement. Experimental verification is provided throughout for all the relevant aspects