Wind turbine induction generator bearing fault detection using stator current analysis By School of...
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Wind turbine induction generator bearing fault detection using
stator current analysis
By
School of Electrical and Electronic Engineering The University of Manchester
D.S. Vilchis-Rodriguez, S. Djurovic, A.C. Smith
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Content
1. Wind generator failure figures
2. Ball bearing frequencies
3. Mathematical model
4. Simulation results
5. Experimental results
6. Fault detection improvement
7. Conclusions
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Wind turbine reliability
Feng Y. and Tavner P., “Introduction to Wind Turbines and their Reliability & Availability”, Warsaw, EWEC 2010, 2010.
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Wind generator failure occurrence
1-2 MW >2 MW
Alewine K. and Chen W., “Wind Turbine Generator Failure Modes Analysis and Occurrence”, Windpower 2010, Dallas, Texas, May 24-26, 2010.
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Rolling bearing race frequencies
1 cos2b b
o rc
N Df f
D
Outer race Inner race
1 cos2b b
i rc
N Df f
D
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Bearing fault mechanical effects
Shaft displacement Rolling element drop
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Air-gap modulation
Air-gap variations Periodic eccentricity
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IG modelling for condition monitoring purposes
• Based on coupled-circuit approach
• Localized bearing faults are modelled as temporary eccentricity variations
• Axial asymmetry is taken into account in the model by averaging both machine ends eccentricity
• This approach makes it possible to analyze with detail incipient bearing faults
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Bearing fault simulation results
0 50 100 150 200 250 300 350 400 450 500
10-6
10-4
10-2
100
stator current frequency spectrum
I s [n
orm
alize
d]
Frequency [Hz]
healthy1 mm2 mm3 mm4 mm5 mm6 mm7 mm
fo- f
s
fundamental
fs+ f
o
2fo- f
s 3fo - f
s
fs + 2fo
slot harmonicslot harmonic
fs + 3f
o
4fo - f
s5f
o - f
s
fs + 4f
o
6fo - f
s
fs + 5f
o
127 128 129 130 131 132 133 134 135 136 137
10-5
stator current frequency spectrum
I s [no
rm
alized
]
Frequency [Hz]
healthy1 mm2 mm3 mm4 mm5 mm6 mm7 mm
fs+f
o
Stator current frequency spectrum
Principal bearing fault frequency
detail
f s of f kf
1,2,3...k
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Test rig layout
Laboratory test bed(viewed from above)
Load side bearing
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Test rig description
Artificial bearing fault Test rig bearing data
Drive-end Non-drive-end
SKF 6313 SKF 6214
Nb = 8 Nb = 10
fo=3.07fr fo=4.11fr
fi=4.93fr fi=5.89fr
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Bearing faultMeasured Frequency spectrum
Vibration spectrumStator line current spectrum
110 115 120 125 130 1350
0.5
1
1.5
2
2.5x 10-3 Stator current frequency spectrum, 1600 rpm
Frequency [Hz]
I s [n
orm
aliz
ed
]
healthyfaulthy
2fo-f
sfo+f
s
80 90 100 110 120 130 140 150 160 170
10-4
10-3
10-2
10-1
100
Frequency [Hz]
Acc
ele
ratio
n [
m/s
2]
Vibration frequency spectrum 1600 rpm
healthyfaulthy
2fo
fo
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Instantaneous complex current signal
0 0.02 0.04 0.06 0.08 0.1-2
-1.5
-1
-0.5
0
0.5
1
1.5
2
Time [s]
Ma
gn
itud
e [
no
rma
lize
d]
Intantaneous complex signal
is(t)
is(t-t)
magnitude (envelope)
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Stator current and current envelope frequency spectrums
127 128 129 130 131 132 133 134 135 1360
0.5
1
1.5
2x 10
-3 Is normalized frequency spectrum
Frequency [Hz]
I s [nor
mal
ized
]
77 78 79 80 81 82 83 84 85 860
0.005
0.01
0.015
0.02
0.025Complex envelope spectrum
Frequency [Hz]
mag
nitu
de [n
orm
aliz
ed]
faulthyhealthy
faulthyhealthy
fo
fs+f
oStator current
spectrum
Complex signalmagnitudespectrum
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Complex signal magnitude frequency spectrumper phase
Stator currentsComplex signal magnitude spectrum
81 82 83 84 85 860
2
4
6
8
10
12
14
16
x 10-3 Complex envelope frequency spectrum, 1630 rpm
Frequency [Hz]
ma
gn
itud
e [
no
rma
lize
d]
Ias
Ibs
Ics
fo
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Instantaneous negative sequence magnitude
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Instantaneous symmetrical components
02
2
1 1 111
31
a
b
c
I t i t
I t a a i t
I t a a i t
02
2
1 1 111
31
a a
b b
c c
I t i t ji t t
I t a a i t ji t t
I t a a i t ji t t
Real valued instantaneous symmetrical components
Complex valued instantaneous symmetrical components
2
3j
a e
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Complex signals frequency spectrum
0
0.02
0.04
0.06
mag
nitu
de
Frequency spectrum, 1630 rpm
0
1
2
3
4x 10
-3
mag
nitu
de
79 80 81 82 83 84 85 86 87 880
0.005
0.010
0
0.005
Frequency [Hz]
mag
nitu
de
fo
fo
fo
a) Current envelope spectrum average
b) Complex valued Instantaneous
negative sequence spectrum
c) Real valued Instantaneous
negative sequence spectrum
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Fault severity analysis
Artificial bearing fault Fault frequency amplitude variation
0 1 2 3 4 5 6 71
1.5
2
2.5
3
3.5
4
4.5
5x 10-3
Defect width [mm]
f o a
mp
litu
de
[n
orm
aliz
ed
]
Fault frequency amplitude versus fault severity
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Conclusions
• An IG analytical model was developed and a commercial machine test rig was used to verify the findings
• Research shows that there are frequency components in IG steady state stator current that are directly related to existence of bearing fault.
• Simulation and experimental data indicate that conventional CSA is not well suited for bearing fault detection.
• The use of complex signals is shown to considerably improve the fault detection using stator current analysis.
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Thank You