Motor fault diagnosis device based on current signal real-time processing

Abstract

The utility model discloses a motor fault diagnosis device based on current signal real-time processing. The motor fault diagnosis device comprises a current signal acquisition module, a data communication and processing module and a motor fault diagnosis system module. According to the utility model, the current signal acquisition module acquires real-time current signals during operation of the motor, the data communication and processing module realizes control of sampling frequency and sampling time by using a digital signal processing and control device, and the acquired current data is processed and then sent to the motor fault diagnosis system module to realize fault diagnosis of the motor. According to the utility model, real-time multi-phase current signals of the motor can be collected, the running state of the motor can be monitored in real time, and motor faults can be identified on line; according to the modular design, diagnosis of various faults and fault severity estimation can be realized by replacing digital signal processors with different performances and different fault diagnosis algorithms, and effective information is provided for subsequent motor fault-tolerant control or fault maintenance.

Description

Technical Field

[0001] The utility model relates to a motor fault diagnosis device based on real-time current processing, belonging to the technical field of motor fault diagnosis. Background Art

[0002] With the widespread application of motors in the industrial field, motor fault diagnosis technology has gradually become a hot research direction in the motor field. In production and life, when a motor fails, it must be diagnosed in time and reasonable disposal measures must be taken to minimize the loss. Therefore, real-time performance is an important indicator of fault diagnosis technology. At present, there are many online fault diagnosis algorithms, but most of them have only been studied theoretically, and there is no corresponding hardware supporting device for practical application. At the same time, the current motor fault diagnosis algorithm still uses existing data sets for offline verification during the research process, and the data set is relatively single, and the generalization and real-time performance of the algorithm cannot be verified. Therefore, designing a fault diagnosis device that can realize real-time diagnosis of motor faults is of great significance for both industrial applications and scientific research. Utility Model Content

[0003] The purpose of the utility model is to provide a motor fault diagnosis device based on real-time current processing, which can simultaneously collect multi-phase current signals, and process and analyze the collected signals to realize online diagnosis of motor faults, so as to solve the problems mentioned in the above background technology.

[0004] To solve the above technical problems, the utility model adopts the following technical solutions: a motor fault diagnosis device based on real-time current processing, including a current signal acquisition module, a data communication processing module, a fault diagnosis system module, a display setting module, and a motor control system; the input end of the current signal acquisition module is connected to the phase current of the motor, the output end of the current signal acquisition module is connected to the differential current input I / O interface of the data communication processing module, and the output end of the data communication processing module is connected to the input end of the fault diagnosis system module; the output end of the fault diagnosis system module is connected to the input end of the display setting module, and the output end of the display setting module is connected to the motor control system.

[0005] Furthermore, the data communication processing module uses a digital signal processing and control device to control the sampling frequency and sampling time, and processes the collected current data and sends it to the fault diagnosis system module to realize motor fault diagnosis. The input end of the data communication and processing module is connected to the differential current output end of the current signal acquisition module.

[0006] Furthermore, the fault diagnosis system module performs real-time analysis on the collected current signal by calling different fault diagnosis algorithm modules to realize fault diagnosis.

[0007] Furthermore, the display setting module is used to display the type and severity of the fault diagnosis.

[0008] Furthermore, the motor control system shuts down the motor or switches the motor control mode according to the fault diagnosis information, and an input end of the motor control system is connected to the output end of the display setting module.

[0009] Further, the current signal acquisition module includes a current differential circuit, which includes a low-distortion differential ADC driver AD8138, wherein pin 1 of the low-distortion differential ADC driver AD8138 is connected to one end of a resistor R135, and the other end of the resistor R135 is connected to AGND; pin 2 of the driver AD8138 is connected to AGND; pin 3 of the driver AD8138 is connected to one end of a capacitor C95 and a capacitor C97, and is connected to a +5V power supply, and the other ends of the capacitors C95 and C97 are connected to AGND; pins 4 and 5 of the driver AD8138 are connected to resistors R138 and R135, respectively. One end of the AD8138 and the other end of the resistor R133 are connected to the differential current input I / O interface of the data communication processing module respectively, and the output signals of the two ports are the differential current signals ADCINI+ and ADCINI- respectively; the 6th foot of the driver AD8138 is connected to one end of the capacitor C116 and the capacitor C109, and is connected to a -5V power supply, and the other ends of the capacitors C116 and C109 are connected to AGND; the 8th foot of the driver AD8138 is connected to one end of the resistor R132, and the other end of the resistor R132 is connected to the input current signal processed by the dual operational amplifier LM358.

[0010] Further, the current signal acquisition module also includes an overcurrent warning circuit, which includes a dual operational amplifier and a voltage comparator. Pin 2 of the voltage comparator U33A is connected to the resistor R144 and one end of the capacitor C133, and the output signal is a positive half-cycle overcurrent warning signal. The other ends of the resistor R144 and the capacitor C133 are respectively connected to the +5V power supply AGND; Pin 3 of the voltage comparator U33A is connected to one end of the capacitor C125 and the capacitor C118, and is connected to the +5V power supply, and the other ends of the capacitors C125 and C118 are connected to AGND; Pin 5 of the voltage comparator U33A is connected to D31 and one end of the resistor R147, which is the input current signal processed by the dual operational amplifier LM358; Pin 12 of the voltage comparator U33A is connected to AGND;

[0011] The function of the dual operational amplifier U29B is to reverse the current in the negative half cycle. Pin 5 of the dual operational amplifier U29B is connected to one end of the resistor R153, and the other end of the resistor R153 is connected to AGND; Pin 6 of the dual operational amplifier U29B is connected to one end of the resistor R158 and the resistor R161, and the other ends of the resistor R158 and the resistor R161 are respectively connected to the input current signal and pin 7 of the dual operational amplifier U29B; Pin 1 of the voltage comparator U33B is connected to one end of the resistor R155 and the capacitor C140, and the other ends of the resistor R155 and the capacitor C140 are respectively connected to the +5V power supply and AGND, and the output signal is an over-current warning signal for the negative half cycle.

[0012] The utility model is a motor fault diagnosis device based on real-time current processing, which has the following advantages: it can collect up to nine-phase current, can perform online diagnosis of motor faults based on real-time processing of current signals, identify the specific type of fault and the severity of the fault and switch to a suitable motor control mode. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 : System principle diagram in the embodiment of the utility model.

[0014] Figure 2 : Schematic diagram of the differential circuit for collecting single-phase current signals and the overcurrent warning circuit in the current signal acquisition module. DETAILED DESCRIPTION Specific embodiment 1

[0016] Specific embodiment 1, a motor fault diagnosis device based on real-time current processing, includes a current signal acquisition module, a data communication processing module, and a fault diagnosis system module. The system schematic diagram is as follows Figure 1 The specific implementation of this embodiment will be described in detail below in conjunction with the accompanying drawings.

[0017] The input end of the current signal acquisition module is connected to the phase current of the motor and is powered by an external ±15V DC isolation power supply. The output end of the current signal acquisition module is connected to the differential current input I / O interface of the data communication processing module, and up to nine phases of current can be measured simultaneously.

[0018] The current signal acquisition module includes a current differential circuit, which includes a low-distortion differential ADC driver AD8138. Pin 1 of the low-distortion differential ADC driver AD8138 is connected to one end of a resistor R135, and the other end of the resistor R135 is connected to AGND; Pin 2 of the driver AD8138 is connected to AGND; Pin 3 of the driver AD8138 is connected to one end of a capacitor C95 and a capacitor C97, and is connected to a +5V power supply, and the other ends of the capacitors C95 and C97 are connected to AGND; Pins 4 and 5 of the driver AD8138 are connected to resistors R138 and R133 respectively. One end of the resistor R138 and the other end of the resistor R133 are respectively connected to the differential current input I / O interface of the data communication processing module, and the output signals of the two ports are the differential current signals ADCINI+ and ADCINI- respectively; the 6th foot of the driver AD8138 is connected to one end of the capacitor C116 and the capacitor C109, and is connected to a -5V power supply, and the other end of the capacitor C116 and C109 is connected to AGND; the 8th foot of the driver AD8138 is connected to one end of the resistor R132, and the other end of the resistor R132 is connected to the input current signal processed by the dual operational amplifier LM358.

[0019] The current signal acquisition module also includes an overcurrent warning circuit, which includes a dual operational amplifier LM358 and a voltage comparator LM2901. Pin 2 of the voltage comparator U33A is connected to resistor R144 and one end of capacitor C133, and the output signal is a positive half-cycle overcurrent warning signal. The other ends of resistor R144 and capacitor C133 are respectively connected to a +5V power supply and AGND; pin 3 of the voltage comparator U33A is connected to one end of capacitor C125 and capacitor C118, and is connected to a +5V power supply, and the other ends of capacitors C125 and C118 are connected to AGND; pin 5 of the voltage comparator U33A is connected to D31 and one end of resistor R147, which is the input current signal processed by the dual operational amplifier LM358; pin 12 of the voltage comparator U33A is connected to AGND. The function of the dual operational amplifier U29B is to reverse the current in the negative half cycle. The 5th pin of the dual operational amplifier U29B is connected to one end of the resistor R153, and the other end of the resistor R153 is connected to AGND. The 6th pin of the dual operational amplifier U29B is connected to one end of the resistor R158 and the resistor R161, and the other ends of the resistor R158 and the resistor R161 are respectively connected to the input current signal and the 7th pin. The 1st pin of the voltage comparator U33B is connected to one end of the resistor R155 and the capacitor C140, and the other ends of the resistor R155 and the capacitor C140 are respectively connected to the +5V power supply and AGND, and the output signal is the over-current warning signal of the negative half cycle.

[0020] In order to meet the needs of multi-phase motor fault diagnosis and ensure that the module has a certain degree of redundancy, the current signal acquisition module has a total of nine-phase current acquisition circuits, and each circuit is independent of each other; in order to ensure power supply stability, a power supply method in which each three-phase circuit shares one power supply can also be adopted.

[0021] The data communication processing module uses dSPACE to control the sampling frequency and sampling time, and processes the collected current data and sends it to the fault diagnosis system module to realize motor fault diagnosis; dSPACE has rich I / O interfaces, powerful computing and processing performance, and a wide adjustable sampling frequency range, which can meet the data requirements of the fault diagnosis algorithm. The input end of the data communication processing module is connected to the differential current output end of the current signal acquisition module.

[0022] The core of the fault diagnosis system module is the fault diagnosis algorithm. The collected and processed current signal is sent to the mature convolutional neural network CNN algorithm module (directly calling the algorithm module of the existing technology) for fault diagnosis and severity estimation. By writing different fault diagnosis algorithms, various fault diagnosis requirements can be achieved. The input end of the fault diagnosis system module is connected to the output end of the data communication and processing module.

[0023] The display setting module is used to display information such as the type and severity of the fault diagnosis. At the same time, an alarm light is provided at the front end, which can also be replaced by a buzzer to realize a sound alarm. When the display setting module receives the motor fault information, it will send a high-level trigger signal. The input end of the display setting module is connected to the output end of the fault diagnosis system module, and the output end of the display setting is connected to the input end of the motor control system.

[0024] The motor control system can shut down the motor or switch the motor control mode according to the signal transmitted by the display setting module. dSPACE can realize current sampling and motor control at the same time, thereby ensuring the real-time performance of the entire device. One input end of the motor control system is connected to the output end of the display setting module.

[0025] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0026] Although the embodiments of the present invention have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A motor fault diagnosis device based on real-time processing of current signals, characterized in that: It includes a current signal acquisition module, a data communication processing module, a fault diagnosis system module, a display setting module, and a motor control system; the input end of the current signal acquisition module is connected to the phase current of the motor, the output end of the current signal acquisition module is connected to the differential current input I / O interface of the data communication processing module, and the output end of the data communication processing module is connected to the input end of the fault diagnosis system module; the output end of the fault diagnosis system module is connected to the input end of the display setting module, and the output end of the display setting module is connected to the motor control system.

2. The motor fault diagnosis device based on real-time processing of current signals according to claim 1 is characterized in that: The data communication processing module uses a digital signal processing and control device to control the sampling frequency and sampling time, and processes the collected current data and sends it to the fault diagnosis system module to realize motor fault diagnosis. The input end of the data communication and processing module is connected to the differential current output end of the current signal acquisition module.

3. The motor fault diagnosis device based on real-time processing of current signals according to claim 1 is characterized in that: The fault diagnosis system module realizes fault diagnosis by calling different fault diagnosis algorithm modules to perform real-time analysis on the collected current signal.

4. The motor fault diagnosis device based on real-time processing of current signals according to claim 1 is characterized in that: The display setting module is used to display the type and severity of the fault diagnosis.

5. The motor fault diagnosis device based on real-time processing of current signals according to claim 1 is characterized in that: The motor control system shuts down the motor or switches the motor control mode according to the fault diagnosis information, and an input end of the motor control system is connected to the output end of the display setting module.

6. The motor fault diagnosis device based on real-time current signal processing according to claim 1 is characterized in that: The current signal acquisition module includes a current differential circuit, which includes a low-distortion differential ADC driver AD8138. Pin 1 of the low-distortion differential ADC driver AD8138 is connected to one end of a resistor R135, and the other end of the resistor R135 is connected to AGND; Pin 2 of the driver AD8138 is connected to AGND; Pin 3 of the driver AD8138 is connected to one end of a capacitor C95 and a capacitor C97, and is connected to a +5V power supply, and the other ends of the capacitors C95 and C97 are connected to AGND; Pins 4 and 5 of the driver AD8138 are connected to resistors R138 and R133 respectively. One end of the resistor R138 and the other end of the resistor R133 are respectively connected to the differential current input I / O interface of the data communication processing module, and the output signals of the two ports are the differential current signals ADCINI+ and ADCINI- respectively; the 6th foot of the driver AD8138 is connected to one end of the capacitor C116 and the capacitor C109, and is connected to a -5V power supply, and the other end of the capacitor C116 and C109 is connected to AGND; the 8th foot of the driver AD8138 is connected to one end of the resistor R132, and the other end of the resistor R132 is connected to the input current signal processed by the dual operational amplifier LM358.

7. The motor fault diagnosis device based on real-time current signal processing according to claim 6 is characterized in that: The current signal acquisition module also includes an overcurrent warning circuit, which includes a dual operational amplifier and a voltage comparator. Pin 2 of the voltage comparator U33A is connected to a resistor R144 and one end of a capacitor C133, and the output signal is a positive half-cycle overcurrent warning signal. The other ends of the resistor R144 and the capacitor C133 are connected to a +5V power supply and AGND respectively; Pin 3 of the voltage comparator U33A is connected to one end of a capacitor C125 and a capacitor C118, and is connected to a +5V power supply, and the other ends of the capacitors C125 and C118 are connected to AGND; Pin 5 of the voltage comparator U33A is connected to D31 and one end of a resistor R147, which is an input current signal processed by the dual operational amplifier LM358; Pin 12 of the voltage comparator U33A is connected to AGND; The function of the dual operational amplifier U29B is to reverse the current in the negative half cycle. Pin 5 of the dual operational amplifier U29B is connected to one end of the resistor R153, and the other end of the resistor R153 is connected to AGND; Pin 6 of the dual operational amplifier U29B is connected to one end of the resistor R158 and the resistor R161, and the other ends of the resistor R158 and the resistor R161 are respectively connected to the input current signal and pin 7 of the dual operational amplifier U29B; Pin 1 of the voltage comparator U33B is connected to one end of the resistor R155 and the capacitor C140, and the other ends of the resistor R155 and the capacitor C140 are respectively connected to the +5V power supply and AGND, and the output signal is an over-current warning signal for the negative half cycle.

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