Detection of backlash phenomena appearing in a single cement kiln drive using the current and the electromagnetic torque signature

IEEE Transactions on Industrial Electronics

Volumn 60, Issue 8, 2013, Pages 3441-3453

  Bogiatzidis, Ioannis X ^a   Safacas, Athanasios N ^a   Mitronikas, Epaminondas D ^a  

^a UNIVERSITY OF PATRAS   (Greece)

Author keywords

AC machines; backlash phenomena; cement kilns; current measurement; discrete Fourier transforms; fault diagnosis; motor current signature analysis (MCSA); motor drive; torque estimation; vibration measurement; voltage measurement

Indexed keywords

AC GENERATOR MOTORS; AIR POLLUTION CONTROL; DISCRETE FOURIER TRANSFORMS; DRIVES; ELECTRIC CURRENT MEASUREMENT; ELECTRIC DRIVES; ELECTROMAGNETISM; FAILURE ANALYSIS; GEARS; INDUCTION MOTORS; TORQUE MOTORS; VIBRATION MEASUREMENT; VIBRATIONS (MECHANICAL); VOLTAGE MEASUREMENT;

AC MACHINE; BACKLASH PHENOMENA; CEMENT KILN; MOTOR CURRENT SIGNATURE ANALYSIS; MOTOR DRIVE; TORQUE ESTIMATION;

KILNS;

EID: 84876236289     PISSN: 02780046     EISSN: None     Source Type: Journal    
DOI: 10.1109/TIE.2012.2194950     Document Type: Article

References (60)

1. A. Bellini, F. Filippetti, C. Tassoni, and G. A. Capolino, "Advances in diagnostic techniques for induction machines," IEEE Trans. Ind. Electron., vol. 55, no. 12, pp. 4109-4126, Dec. 2008.
2. M. El Hachemi Benbouzid, "A review of induction motors signature analysis as a medium for faults detection," IEEE Trans. Ind. Electron., vol. 47, no. 5, pp. 984-993, Oct. 2000.
3. S. Nandi, H. A. Toliyat, and L. Xiaodong, "Condition monitoring and fault diagnosis of electrical motors-A review," IEEE Trans. Energy Convers., vol. 20, no. 4, pp. 719-729, Dec. 2005. (Pubitemid 41830047)
4. J. S. Hsu, "Monitoring of defects in induction motors through air-gap torque observation," IEEE Trans. Ind. Appl., vol. 31, no. 5, pp. 1016-1021, Sep./Oct. 1995.
5. M. Riera-Guasp, J. A. Antonino-Daviu, J. Roger-Folch, and M. P. Molina Palomares, "The use of the wavelet approximation signal as a tool for the diagnosis of rotor bar failures," IEEE Trans. Ind. Appl., vol. 44, no. 3, pp. 716-726, May/Jun. 2008. (Pubitemid 351796118)
6. S. H. Kia, H. Henao, and G. A. Capolino, "Diagnosis of broken-bar fault in induction machines using discrete wavelet transform without slip estimation," IEEE Trans. Ind. Appl., vol. 45, no. 4, pp. 1395-1404, Jul./Aug. 2009.
7. S. Chen and R. Zivanovic, "Estimation of frequency components in stator current for the detection of broken rotor bars in induction machines," Measurement, vol. 43, no. 7, pp. 887-900, Aug. 2010.
8. T. M. Wolbank, P. Nussbaumer, C. Hao, and P. E. Macheiner, "Monitoring of rotor-bar defects in inverter-fed induction machines at zero load and speed," IEEE Trans. Ind. Electron., vol. 58, no. 5, pp. 1468-1478, May 2011.
9. G. M. Joksimovic and J. Penman, "The detection of inter-turn short circuits in the stator windings of operating motors," IEEE Trans. Ind. Electron., vol. 47, no. 5, pp. 1078-1084, Oct. 2000.
10. F. Zidani, M. E. H. Benbouzid, D. Diallo, and M. S. Naït-Saïd, "Induction motor stator faults diagnosis by a current Concordia pattern-based fuzzy decision system," IEEE Trans. Energy Convers., vol. 18, no. 4, pp. 469-475, Dec. 2003.
11. C. Xianrong, V. Cocquempot, and C. Christophe, "A model of asynchronous machines for stator fault detection and isolation," IEEE Trans. Ind. Electron., vol. 50, no. 3, pp. 578-584, Jun. 2003.
12. S. Cheng, P. Zhang, and T. G. Habetler, "An impedance identification approach to sensitive detection and location of stator turn-to-turn faults in a closed-loop multiple-motor drive," IEEE Trans. Ind. Electron., vol. 58, no. 5, pp. 1545-1554, May 2011.
13. R. R. Schoen and T. G. Habetler, "Effects of time-varying loads on rotor fault detection in induction machines," IEEE Trans. Ind. Appl., vol. 31, no. 4, pp. 900-906, Jul./Aug. 1995.
14. G. M. Joksimovic, M. D. Durovic, J. Penman, and N. Arthur, "Dynamic simulation of dynamic eccentricity in induction machines-winding function approach," IEEE Trans. Energy Convers., vol. 15, no. 2, pp. 143-148, Jun. 2000.
15. S. Nandi, R. M. Bharadwaj, and H. A. Toliyat, "Performance analysis of a three-phase induction motor under mixed eccentricity condition," IEEE Trans. Energy Convers., vol. 17, no. 3, pp. 392-399, Sep. 2002. (Pubitemid 35151676)
16. G. M. Joksimovic, "Dynamic simulation of cage induction machine with air gap eccentricity," Proc. Inst. Elect. Eng.-Elect. Power Appl., vol. 152, no. 4, pp. 803-811, Jul. 2005. (Pubitemid 41067896)
17. S. Nandi, T. C. Ilamparithi, L. S. Bin, and H. Doosoo, "Detection of eccentricity faults in induction machines based on nameplate parameters," IEEE Trans. Ind. Electron., vol. 58, no. 5, pp. 1673-1683, May 2011.
18. L. Eren andM. J. Devaney, "Bearing damage detection via wavelet packet decomposition of the stator current," IEEE Trans. Instrum. Meas., vol. 53, no. 2, pp. 431-436, Apr. 2004.
19. M. J. Devaney and L. Eren, "Detecting motor bearing faults," IEEE Instrum. Meas. Mag., vol. 7, no. 4, pp. 30-50, Dec. 2004.
20. C. Bianchini, F. Immovilli, M. Cocconcelli, R. Rubini, and A. Bellini, "Fault detection of linear bearings in brushless ac linear motors by vibration analysis," IEEE Trans. Ind. Electron., vol. 58, no. 5, pp. 1684-1694, May 2011.
21. C. A. Michael and A. N. Safacas, "Dynamic and vibration analysis of a multimotor dc drive system with elastic shafts driving a tissue paper machine," IEEE Trans. Ind. Electron., vol. 54, no. 4, pp. 2033-2046, Aug. 2007. (Pubitemid 47271277)
22. D. A. Fenton, R. M. Taylor, D. C. Salzborn, and C. B. Mayer, "Torsional vibration analysis and comprehensive field testing on a large rotary kiln," IEEE Trans. Ind. Appl., vol. IA-21, no. 4, pp. 1030-1038, Jul./Aug. 1985. (Pubitemid 16479571)
23. I. P. Tsoumas, G. Georgoulas, E. D. Mitronikas, and A. N. Safacas, "Asynchronous machine rotor fault diagnosis technique using complex wavelets," IEEE Trans. Energy Convers., vol. 23, no. 2, pp. 444-459, Jun. 2008. (Pubitemid 351728785)
24. I. Tsoumas, E. Mitronikas, G. Georgoulas, and A. Safacas, "A comparative study of induction motor current signature analysis techniques for mechanical faults detection," in Proc. IEEE SDEMPED, Vienna, Austria, Sep. 7-9, 2005, pp. 1-6.
25. K. Szabat and T. Orlowska-Kowalska, "Vibration suppression in a two-mass drive system using PI speed controller and additional feedbacks-Comparative study," IEEE Trans. Ind. Electron., vol. 54, no. 2, pp. 1193-1206, Apr. 2007. (Pubitemid 46591040)
26. M. Itoh, "Vibration suppression control for a twin-drive geared system: Simulation study on effects of model-based control integrated into the position control loop," in Proc. ICIMA, Chengdu, China, Aug. 26-31, 2004, pp. 196-201.
27. S. H. Kia, H. Henao, and G. A. Capolino, "A high-resolution frequency estimation method for three-phase induction machine fault detection," IEEE Trans. Ind. Electron., vol. 54, no. 4, pp. 2305-2314, Aug. 2007. (Pubitemid 47296521)
28. A. Bellini, A. Yazidi, F. Filippetti, C. Rossi, and G. A. Capolino, "High frequency resolution techniques for rotor fault detection of induction machines," IEEE Trans. Ind. Electron., vol. 55, no. 12, pp. 4200-4209, Dec. 2008.
29. J. Pons-Llinares, J. A. Antonino-Daviu, M. Riera-Guasp, M. Pineda-Sanchez, and V. Climente-Alarcon, "Induction motor diagnosis based on a transient current analytic wavelet transform via frequency B-splines," IEEE Trans. Ind. Electron., vol. 58, no. 5, pp. 1530-1544, May 2011.
30. W. J. Staszewski and G. R. Tomlinson, "Application of the wavelet transform to fault detection in a spur gear," Mech. Syst. Signal Process., vol. 8, no. 3, pp. 289-307, May 1994.
31. X. Fan and M. J. Zuo, "Gearbox fault detection using Hilbert and wavelet packet transform," Mech. Syst. Signal Process., vol. 20, no. 4, pp. 966-982, May 2006. (Pubitemid 43121169)
32. H. Li, Y. Zhang, and H. Zheng, "Wear detection in gear system using Hilbert-Huang transform," J. Mech. Sci. Tech., vol. 20, no. 11, pp. 1781-1789, Nov. 2006.
33. N. Baydar and A. Ball, "Detection of gear failures via vibration and acoustic signals using wavelet transform," Mech. Syst. Signal Process., vol. 17, no. 4, pp. 787-804, Jul. 2003.
34. S. Villwock andM. Pacas, "Time domain identification method for detecting mechanical backlash in electrical drives," IEEE Trans. Ind. Electron., vol. 56, no. 2, pp. 568-573, Feb. 2009.
35. A. R. Mohanty and C. Kar, "Fault detection in a multistage gearbox by demodulation of motor current waveform," IEEE Trans. Ind. Electron., vol. 53, no. 4, pp. 1285-1297, Jun. 2006. (Pubitemid 44263739)
36. C. Kar and A. R. Mohanty, "Monitoring gear vibrations through motor current signature analysis and wavelet transform," Mech. Syst. Signal Process., vol. 20, no. 1, pp. 158-187, Jan. 2006. (Pubitemid 41566168)
37. C. Kar and A. R. Mohanty, "Multistage gearbox condition monitoring using motor current signature analysis and Kolmogorov-Smirnov test," J. Sound Vib., vol. 290, no. 1/2, pp. 337-368, Feb. 2006. (Pubitemid 41802252)
38. S. H. Kia, H. Henao, and G. A. Capolino, "Gearbox monitoring using induction machine stator current analysis," in Proc. IEEE SDEMPED, Cracow, Poland, Sep. 6-8, 2007, pp. 149-154.
39. S. H. Kia, H. Henao, and G. A. Capolino, "Analytical and experimental study of gearbox mechanical effect on the induction machine stator current signature," IEEE Trans. Ind. Appl., vol. 45, no. 4, pp. 1405-1415, Jul./Aug. 2009.
40. S. H. Kia, H. Henao, and G. A. Capolino, "A modeling approach for gearbox monitoring using stator current signature in induction machines," in Proc. IEEE IAS, Edmonton, AB, Canada, Oct. 5-9, 2008, pp. 1-6.
41. S. H. Kia, H. Henao, and G. A. Capolino, "Torsional vibration effects on induction machine current and torque signatures in gearbox-based electromechanical system," IEEE Trans. Ind. Electron., vol. 56, no. 11, pp. 4689-4699, Nov. 2009.
42. S. H. Kia, H. Henao, and G. A. Capolino, "Torsional vibration assessment using induction machine electromagnetic torque estimation," IEEE Trans. Ind. Electron., vol. 57, no. 1, pp. 209-219, Jan. 2010.
43. S. H. Kia, H. Henao, and G. A. Capolino, "Torsional vibration assessment in railway traction system mechanical transmission," in Proc. IEEE SDEMPED, Cargese, France, Aug. 31-Sep. 03, 2009, pp. 1-8.
44. H. Henao, S. H. Kia, and G. A. Capolino, "Torsional-vibration assessment and gear-fault diagnosis in railway traction system," IEEE Trans. Ind. Electron., vol. 58, no. 5, pp. 1707-1717, May 2011.
45. S. Rajagopalan, T. G. Habetler, R. G. Harley, T. Sebastian, and B. Lequesne, "Current/voltage-based detection of faults in gears coupled to electric motors," IEEE Trans. Ind. Appl., vol. 42, no. 6, pp. 1412-1420, Nov./Dec. 2006. (Pubitemid 44824041)
46. H. Henein, J. K. Brimacombe, and A. P. Watkinson, "Experimental study of transverse bed motion in rotary kilns," Metall. Mater. Trans. B, vol. 14, no. 2, pp. 191-205, Jun. 1983. (Pubitemid 13538675)
47. I. Bogiatzidis, E. Mitronikas, A. Safacas, and G. Christopoulos, "Realization and development of a laboratory simulating system of a girth gear/common shaft ac drive used in cement industry," in Proc. ACEMP, Bodrum, Turkey, Sep. 10-12, 2007, pp. 788-794.
48. M. Holland, "AC DC kilns drives, cement plant," in Proc. IEEE-IAS/PCA Cement Ind. Tech. Conf., Vancouver, BC, Canada, Apr. 29-May 03, 2001, pp. 75-84.
49. I. X. Bogiatzidis, E. D. Mitronikas, and A. N. Safacas, "Investigation of backlash phenomena appearing in a twin ac cement kiln drive," in Proc. 19th ICEM, Rome, Italy, Sep. 6-8, 2010, pp. 1-6.
50. G. A. Christopoulos and A. N. Safacas, "Upgrade of a kiln drive system for cement industry," in Proc. 19th ICEM, Rome, Italy, Sep. 6-8, 2010, pp. 1-5.
51. G. Seggewiss, N. Schachter, and G. Obermeyer, "Kiln drive application considerations," in Conf. Rec. IEEE Cement Ind. Tech. Conf., May 15-20, 2005, pp. 52-76. (Pubitemid 44160350)
52. A. Lagerberg and B. Egardt, "Backlash estimation with application to automotive powertrains," IEEE Trans. Control Syst. Technol., vol. 15, no. 3, pp. 483-493, May 2007. (Pubitemid 46746267)
53. R. Merzouki and J. C. Cadiou, "Estimation of backlash phenomenon in the electromechanical actuator," Control Eng. Pract., vol. 13, no. 8, pp. 973-983, Aug. 2005. (Pubitemid 40373941)
54. C. B. Mayer, "Torsional vibration problems and analyses of cement industry drives," IEEE Trans. Ind. Appl., vol. IA-17, no. 1, pp. 81-89, Jan./Feb. 1981.
55. S. E. Ehinger, "A kiln drive vibration problem and solution," in Conf. Rec. 35th IEEE Cement Ind. Tech. Conf., Toronto, ON, Canada, May 23-27, 1993, pp. 141-152.
56. D. A. Fenton, "Lateral vibrations, causes and some solutions in electric drive trains," in Conf. Rec. 35th IEEE Cement Ind. Tech. Conf., Toronto, ON, Canada, May 23-27, 1993, pp. 105-132.
57. J. T. Price, "Vibration analysis methods for preventative maintenance of cement plants," in Proc. IEEE-IAS/PCA Cement Ind. Tech. Conf., Vancouver, BC, Canada, Apr. 23-May 03 2001, pp. 333-341.
58. R. Yacamini, K. S. Smith, and L. Ran, "Monitoring torsional vibrations of electro-mechanical systems using stator currents," Trans. ASME J. Vib. Acoust., vol. 120, no. 1, pp. 72-79, Jan. 1998. (Pubitemid 128651960)
59. M. Blödt, M. Chabert, J. Regnier, and J. Faucher, "Mechanical load fault detection in induction motors by stator current time-frequency analysis," IEEE Trans. Ind. Appl., vol. 42, no. 6, pp. 1454-1463, Nov./Dec. 2006. (Pubitemid 44824046)
60. I. X. Bogiatzidis, E. D. Mitronikas, and A. N. Safacas, "DTC based control strategy of a twin ac drive used for a cement kiln," Int. Rev. Elect. Eng., vol. 5, pt. A, no. 4, pp. 1496-1503, Aug. 2010.