Motor fault detection system
By designing a motor fault detection system that integrates U-phase, V-phase, W-phase detection modules and logic circuits, the problem that traditional methods are difficult to accurately detect phase-break faults in real time is solved, and efficient and accurate fault detection and prevention is achieved, ensuring the safe and stable operation of the motor.
Patent Information
- Application Number
- CN202421890483.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-06
- Publication Date
- 2025-06-17
- Estimated Expiration
- 2034-08-06
AI Technical Summary
Traditional motor fault detection methods are difficult to accurately detect phase failures in real time, resulting in unstable motor operation, which may cause serious consequences such as overheating, aggravation of vibration, reduced load capacity, and even burning.
A motor fault detection system is designed, including U-phase detection module, V-phase detection module, W-phase detection module, AND gate, NOR gate, OR gate and main control module. The operation status of three-phase electricity is monitored in real time through logic circuits, and the low-level signal is quickly output after phase disconnection is detected, triggering the main control module to respond to the fault.
Real-time monitoring of the three-phase electric operating status of the motor and accurate phase-break fault judgment, improve the sensitivity and accuracy of fault detection, simplify the logical process of fault judgment, effectively prevent serious consequences caused by phase-break faults, ensure the safe and stable operation of the motor, reduce maintenance costs, and extend the service life of the equipment.
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Figure CN222994619U_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to the technical field of electric motors, and in particular, to an electric motor fault detection system. Background Art
[0002] In modern industrial production, as a key component for driving various mechanical equipment, the stability and reliability of an electric motor are directly related to production efficiency and safety. However, during operation, electric motors often fail due to various reasons, among which open-phase faults are particularly common and harmful. An open-phase fault not only causes the stator rotating magnetic field of the electric motor to become unbalanced, generating negative-sequence current and magnetic field, leading to a sharp increase in rotor current and overheating, but also may significantly reduce the load-carrying capacity of the electric motor, exacerbate motor vibration and noise, and even cause damage to bearings and the machine base, seriously affecting the normal operation of the production line.
[0003] Traditional methods for detecting electric motor faults mostly rely on manual inspections and regular maintenance, which are not only inefficient but also difficult to detect potential faults such as open phases in real time and accurately. Utility Model Content
[0004] Embodiments of the present disclosure provide an electric motor fault detection system to solve the problem that traditional electric motor fault detection means are difficult to detect open-phase faults in real time and accurately.
[0005] Embodiments of the present disclosure provide an electric motor fault detection system, including a U-phase detection module, a V-phase detection module, a W-phase detection module, an AND gate, a NOR gate, an OR gate, and a main control module;
[0006] The first input terminal of the AND gate is connected to the U-phase detection module, the second input terminal of the AND gate is connected to the V-phase detection module, and the third input terminal of the AND gate is connected to the W-phase detection module;
[0007] The first input terminal of the NOR gate is connected to the U-phase detection module, the second input terminal of the NOR gate is connected to the V-phase detection module, and the third input terminal of the NOR gate is connected to the W-phase detection module;
[0008] The output terminal of the AND gate is connected to the first input terminal of the OR gate, the output terminal of the NOR gate is connected to the second input terminal of the OR gate, and the output terminal of the OR gate is respectively connected to the first input terminal of the AND gate and the first input terminal of the NOR gate;
[0009] The U-phase detection module is used to detect the U-phase electricity, the V-phase detection module is used to detect the V-phase electricity, and the W-phase detection module is used to connect the W-phase electricity.
[0010] In an exemplary embodiment of the present disclosure, a warning module is further included;
[0011] The warning module is connected to the main control module.
[0012] In an exemplary embodiment of the present disclosure, a protection module is further included;
[0013] The protection module is connected to the main control module.
[0014] In an exemplary embodiment of the present disclosure, a communication module is further included;
[0015] The main control module is communicatively connected to the monitoring terminal through the communication module.
[0016] In an exemplary embodiment of the present disclosure, the circuit structures of the U-phase detection module, the V-phase detection module, and the W-phase detection module are the same. The U-phase detection module includes a current transformer L1, a diode D1, a variable resistor RP1, a capacitor C1, a resistor R1, a resistor R2, a zener diode D2, and an operational amplifier U1;
[0017] The first end of the current transformer L1 is connected to the anode of the diode D1, the second end of the current transformer L1 is grounded, the cathode of the diode D1 is connected to the first end of the variable resistor RP1, the second end of the variable resistor RP1 is grounded, the sliding end of the variable resistor RP1 is grounded through the capacitor C1, and the sliding end of the variable resistor RP1 is connected to the non-inverting input terminal of the operational amplifier U1;
[0018] The first end of the resistor R1 is used to connect to the VCC power supply, the second end of the resistor R1 is grounded through the resistor R2, the second end of the resistor R1 is connected to the inverting input terminal of the operational amplifier U1, the cathode of the zener diode D2 is connected to the first end of the resistor R1, the anode of the zener diode D2 is grounded, and the output terminal of the operational amplifier U1 is connected to the main control module.
[0019] In an exemplary embodiment of the present disclosure, the protection module includes a triode Q1 and a relay K1;
[0020] The base of the triode Q1 is connected to the main control module, the collector of the triode Q1 is connected to the first power supply terminal of the relay K1, the second power supply terminal of the relay K1 is used to connect to the VDD power supply, and the emitter of the triode Q1 is grounded.
[0021] In an exemplary embodiment of the present disclosure, the protection module further includes a resistor R5, an optocoupler U2, and a resistor R4;
[0022] The first end of the resistor R5 is connected to the main control module, the second end of the resistor R5 is connected to the first input terminal of the optocoupler U2, the second input terminal of the optocoupler U2 is grounded, the first output terminal of the optocoupler U2 is connected to the VDD power supply through the resistor R4, and the second output terminal of the optocoupler U2 is grounded.
[0023] The beneficial effects of the motor fault detection system provided by the embodiments of the present disclosure are as follows:
[0024] By integrating logical circuits such as a U-phase detection module, a V-phase detection module, a W-phase detection module, an AND gate, a NOR gate, and an OR gate, the embodiments of the present disclosure achieve real-time monitoring of the operating states of the three-phase electricity of the motor and accurate open-phase fault judgment. The embodiments of the present disclosure can efficiently convert three-phase AC voltage into DC voltage, and utilize the characteristics of logical gates to output a high-level signal to the main control module when the motor is working properly. Once any phase of electricity is detected to be open-phase, a low-level signal is quickly output through logical operation to trigger the main control module to perform a fault response. This not only improves the sensitivity and accuracy of fault detection, but also simplifies the logical process of fault judgment, effectively preventing serious consequences such as overheating, increased vibration, decreased load-carrying capacity, and even burnout of the motor caused by open-phase faults, ensuring the safe and stable operation of the motor, reducing maintenance costs, and extending the service life of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] In order to more clearly illustrate the technical solutions in the embodiments of the present disclosure, the following will briefly introduce the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings in the following description are only some embodiments of the present disclosure. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.
[0026] Figure 1 is a structural block diagram of the motor fault detection system provided by the embodiments of the present disclosure;
[0027] Figure 2 is a circuit diagram of the U-phase detection module provided by the embodiments of the present disclosure;
[0028] Figure 3 is a circuit diagram of the protection module provided by the embodiments of the present disclosure. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0029] In order to enable those skilled in the art to better understand this solution, the following will clearly describe the technical solutions in the embodiments of this solution in conjunction with the drawings in the embodiments of this solution. Obviously, the described embodiments are some, but not all, of the embodiments of this solution. Based on the embodiments in this solution, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the scope of protection of this solution.
[0030] In the description, claims, and above-mentioned drawings of this solution, the term "including" and any other variations thereof mean "including but not limited to", intending to cover non-exclusive inclusion and not limited only to the examples listed in the text. In addition, terms such as "first" and "second" are used to distinguish different objects rather than to describe a specific order.
[0031] The implementation of the present disclosure will be described in detail below in conjunction with specific drawings:
[0032] Figure 1 It is a schematic structural diagram of a motor fault detection system provided for an embodiment of the present disclosure. Referring to Figure 1 , the motor fault detection system includes a U-phase detection module, a V-phase detection module, a W-phase detection module, an AND gate, a NOR gate, an OR gate, and a main control module; the first input terminal of the AND gate is connected to the U-phase detection module, the second input terminal of the AND gate is connected to the V-phase detection module, and the third input terminal of the AND gate is connected to the W-phase detection module; the first input terminal of the NOR gate is connected to the U-phase detection module, the second input terminal of the NOR gate is connected to the V-phase detection module, and the third input terminal of the NOR gate is connected to the W-phase detection module; the output terminal of the AND gate is connected to the first input terminal of the OR gate, the output terminal of the NOR gate is connected to the second input terminal of the OR gate, and the output terminal of the OR gate is connected to the main control module; the U-phase detection module is used to detect the U-phase electricity, the V-phase detection module is used to detect the V-phase electricity, and the W-phase detection module is used to connect the W-phase electricity.
[0033] A single-phase open fault will cause a serious imbalance in the stator rotating magnetic field of the motor, thereby generating negative-sequence current and negative-sequence magnetic field. These interact with the rotor through electromagnetic induction, causing the rotor current to increase sharply and the rotor to overheat severely. Secondly, the single-phase open fault will cause the load-carrying capacity of the motor to drop sharply, resulting in a sharp increase in the stator current, the motor housing to heat up, and the motor to burn out after long-term operation. In addition, the single-phase open will also cause an increase in the vibration of the motor, generate abnormal noises, and may damage the bearings and the machine base, further exacerbating the damage to the motor. Therefore, in the daily maintenance and repair of the motor, it is necessary to strengthen the detection and prevention of single-phase open faults to ensure the safe and stable operation of the motor.
[0034] In this embodiment, the U-phase detection module, the V-phase detection module, and the W-phase detection module respectively detect the three-phase electricity (i.e., U-phase electricity, V-phase electricity, and W-phase electricity) during the operation of the motor, and convert the AC voltages of the three-phase electricity into appropriate DC voltages and send them to the input terminals of the AND gate and the NOR gate respectively. In this embodiment, the U-phase detection module, the V-phase detection module, and the W-phase detection module can detect the voltage or current of the corresponding phase line. When the motor is connected to the three-phase electricity and operates normally, the U-phase detection module, the V-phase detection module, and the W-phase detection module all output voltage signals, and the three input terminals of the AND gate and the NOR gate are all at high level. Therefore, the AND gate outputs a high level, and the NOR gate outputs a low level. The outputs of the AND gate and the NOR gate are respectively added to the two input terminals of the OR gate. At this time, the OR gate outputs a high level signal and sends it to the main control module. When the motor is powered off, the outputs of the U-phase detection module, the V-phase detection module, and the W-phase detection module are all 0, and the three input terminals of the AND gate and the NOR gate are all at low level. Therefore, the AND gate outputs a low level, and the NOR gate outputs a high level. At this time, the OR gate still outputs a high level signal and sends it to the main control module. When the motor is working, assuming that the W-phase electricity is open-phase, the U-phase detection module and the V-phase detection module normally output voltage signals, and the output of the W-phase detection module is 0. At this time, the output of the AND gate is 0, and the output of the NOR gate is also 0, that is, the two input terminals of the OR gate are both at low level. Therefore, the OR gate outputs a low level and sends it to the main control module. The main control module can judge whether the motor has an open-phase situation according to the level output by the OR gate.
[0035] It can be concluded from the above that in this embodiment, by integrating logic circuits such as the U-phase detection module, the V-phase detection module, the W-phase detection module, the AND gate, the NOR gate, and the OR gate, the real-time monitoring of the operating state of the three-phase electricity of the motor and the accurate open-phase fault judgment are realized. This embodiment can efficiently convert the three-phase AC voltage into a DC voltage, and utilize the characteristics of the logic gates to output a high level signal to the main control module when the motor is working normally. Once an open-phase of any phase of electricity is detected, a low level signal is quickly output through logical operation to trigger the main control module to perform a fault response. This not only improves the sensitivity and accuracy of fault detection, but also simplifies the logical process of fault judgment, effectively preventing serious consequences such as overheating, increased vibration, decreased load-carrying capacity, and even burning of the motor caused by open-phase faults, ensuring the safe and stable operation of the motor, reducing the maintenance cost, and extending the service life of the equipment.
[0036] As Figure 1 shown, in an embodiment of the present disclosure, a warning module is further included; the warning module is connected to the main control module.
[0037] In this embodiment, when the main control module receives the low level output by the OR gate and determines that the motor has a phase loss, it can immediately send a corresponding instruction to the warning module. The warning module can adopt various forms. For example, an audible and visual alarm can emit a loud alarm sound and flashing lights after receiving the instruction to remind the operator that the motor has a fault and needs to be processed in time. Also, for example, the warning module can be a communication module connected to the monitoring system, which can send a fault prompt message to the monitoring room so that the staff can know and take measures immediately. For another example, the warning module can also display prominent fault prompt text or icons on the operation interface to attract the attention of on-site personnel.
[0038] By setting up the warning module, it is possible to timely and effectively notify relevant personnel of the motor fault situation, so as to quickly take maintenance or emergency measures and reduce the losses and risks caused by the fault.
[0039] In this embodiment, the warning module realizes the instant warning of the fault, enabling relevant personnel to respond quickly and take measures to avoid the further expansion of the fault or more serious consequences. At the same time, by receiving the warning information through the remote monitoring center, it also realizes the remote monitoring and management of the motor operation status, improves the efficiency and convenience of maintenance, and further ensures the continuity and safety of the production line.
[0040] As Figure 1 shown, in an embodiment of the present disclosure, a protection module is further included; the protection module is connected to the main control module.
[0041] In this embodiment, once the main control module determines that the motor has a phase loss fault and sends an instruction to the protection module, the protection module can quickly take actions to reduce the damage caused by the fault.
[0042] For example, the protection module can be a device for quickly cutting off the power supply. After receiving the instruction from the main control module, it immediately cuts off the power supply of the motor to prevent the abnormal current from further burning out the motor and avoid possible larger-scale circuit faults and safety hazards.
[0043] In this embodiment, the protection module enhances the emergency response ability of the motor fault detection system, can immediately take effective measures when detecting a fault, and protects the motor and related equipment from damage. This instant protection not only reduces the maintenance cost and time, but also improves the safety and reliability of the production line, providing a strong guarantee for the continuous production and efficient operation of the enterprise.
[0044] As Figure 1 shown, in an embodiment of the present disclosure, a communication module is further included; the main control module is communicatively connected to the monitoring terminal through the communication module.
[0045] In this embodiment, the communication module, acting as a bridge connecting the main control module and the monitoring terminal, can accurately transmit the motor operating status information obtained by the main control module, including whether it is operating normally, whether a phase failure occurs, etc., to the monitoring terminal in real time. This means that relevant staff can remotely and real-time understand the working conditions of the motor at the monitoring terminal without having to be on-site. For example, in a large factory, the operating information of numerous motors distributed in different areas can be centrally transmitted to the monitoring terminal in the central monitoring room through the communication module. When a phase failure occurs in the motor, the main control module will send an alarm signal to the monitoring terminal through the communication module. The monitoring terminal can display detailed fault information, and the staff can make decisions quickly based on this information and arrange maintenance personnel to go for handling.
[0046] In this embodiment, the communication module and the monitoring terminal achieve remote monitoring of the motor operating status and real-time data transmission, enabling operators and maintenance personnel to master the real-time situation of the motor without having to be on-site. This not only improves work efficiency but also reduces labor costs. At the same time, the remote monitoring function also enables a faster fault response, helping to detect and handle potential problems in a timely manner, thus ensuring the continuity and safety of the production line.
[0047] As Figure 2 shown, in an embodiment of the present disclosure, the circuit structures of the U-phase detection module, the V-phase detection module, and the W-phase detection module are the same. The U-phase detection module includes a current transformer L1, a diode D1, a variable resistor RP1, a capacitor C1, a resistor R1, a resistor R2, a zener diode D2, and an operational amplifier U1; the first end of the current transformer L1 is connected to the anode of the diode D1, the second end of the current transformer L1 is grounded, the cathode of the diode D1 is connected to the first end of the variable resistor RP1, the second end of the variable resistor RP1 is grounded, the sliding end of the variable resistor RP1 is grounded through the capacitor C1, and the sliding end of the variable resistor RP1 is connected to the non-inverting input terminal of the operational amplifier U1; the first end of the resistor R1 is used to connect to the VCC power supply, the second end of the resistor R1 is grounded through the resistor R2, the second end of the resistor R1 is connected to the inverting input terminal of the operational amplifier U1, the cathode of the zener diode D2 is connected to the first end of the resistor R1, the anode of the zener diode D2 is grounded, and the output terminal of the operational amplifier U1 is respectively connected to the first input terminal of the AND gate and the first input terminal of the NOR gate.
[0048] In this embodiment, the filter circuit composed of the rheostat RP1 and the capacitor C1 can smooth the rectified DC signal and reduce the ripple component therein. The sliding end of the rheostat RP1 can adjust the filtering effect and the magnitude of the output signal. The voltage-dividing circuit formed by the resistor R1 and the resistor R2 sets a fixed reference voltage for the inverting input terminal of the operational amplifier U1. The zener diode D2 ensures the stability of this reference voltage and prevents the power supply fluctuation from affecting it. The operational amplifier U1 compares the processed signal received by the non-inverting input terminal with the reference voltage at the inverting input terminal. When the U-phase power supply operates normally, the voltage at the non-inverting input terminal of the operational amplifier U1 is greater than the voltage at the inverting input terminal of the operational amplifier U1, and the operational amplifier U1 outputs a high level. When the U-phase power supply has a phase break during the operation of the motor, the operational amplifier U1 outputs a low level.
[0049] The circuit structure and working principle of the U-phase detection module are equally applicable to the V-phase detection module and the W-phase detection module, which will not be elaborated here.
[0050] As Figure 3 shown, in an embodiment of the present disclosure, the protection module includes a triode Q1 and a relay K1; the base of the triode Q1 is connected to the main control module, the collector of the triode Q1 is connected to the first power supply terminal of the relay K1, the second power supply terminal of the relay K1 is used to connect to the VDD power supply, and the emitter of the triode Q1 is grounded.
[0051] In this embodiment, the working principle of the protection module is based on the switching characteristics of the triode Q1 and the control function of the relay K1. When the main control module detects a phase break fault in the motor, it sends a high-level control signal to the base of the triode Q1. The triode Q1 conducts. At this time, the current flows from the first power supply terminal of the relay K1 through the triode Q1 to the ground, enabling the relay K1 to be energized and operate. After the relay K1 is energized, corresponding protection actions can be achieved, such as disconnecting the power supply circuit of the motor or switching to the standby power supply, etc.
[0052] For example, if the motor has a phase break fault, the main control module outputs a high level to the base of the triode Q1, the triode Q1 conducts, the relay K1 operates, and the power supply of the motor is cut off to avoid further damage to the motor.
[0053] In this embodiment, the protection module realizes fast and reliable protection for the motor. When this embodiment detects that the motor is running with a phase loss, it can quickly cut off the power supply, prevent the expansion of the fault, and protect the motor, the power supply and other equipment from being damaged.
[0054] As Figure 3As shown, in an embodiment of the present disclosure, the protection module further includes a resistor R5, an optocoupler U2, and a resistor R4; the first end of the resistor R5 is connected to the main control module, the second end of the resistor R5 is connected to the first input end of the optocoupler U2, the second input end of the optocoupler U2 is grounded, the first output end of the optocoupler U2 is connected to the VDD power supply through the resistor R4, and the second output end of the optocoupler U2 is grounded.
[0055] In practical applications, the working environment of the motor is relatively complex. To avoid misoperation of the protection module, the optocoupler U2 is added in this embodiment.
[0056] The resistor R5 functions as a current limiter, restricting the current output from the main control module to the input end of the optocoupler U2 to protect the optocoupler U2 from being damaged by excessive current. The optocoupler U2 realizes electrical isolation, electrically isolating the main control module from the subsequent protection circuit to avoid interference and fault propagation. When the main control module outputs a signal to the resistor R5, a current passes through the input end of the optocoupler U2, causing the light-emitting diode inside the optocoupler U2 to emit light, and then causing the triode Q1 at the output end of the optocoupler U2 to conduct. The resistor R4 is used to provide a pull-up resistor for the output end of the optocoupler U2 to ensure that a stable high level can be output when the triode at the output end of the optocoupler U2 conducts.
[0057] In this embodiment, the protection module also realizes electrical isolation between the main control module and the subsequent protection circuit by introducing the optocoupler U2, effectively preventing potential damage to the main control module caused by high voltage, large current, or electromagnetic interference. At the same time, the isolation characteristic of the optocoupler also improves the safety and reliability of this embodiment, making the protection action more accurate and rapid.
[0058] The above embodiments are only used to illustrate the technical solutions of the present disclosure, rather than to limit them; although the present disclosure has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present disclosure.
Claims
1. A motor fault detection system, characterized in that: It includes a U-phase detection module, a V-phase detection module, a W-phase detection module, an AND gate, a NOR gate, an OR gate and a main control module; The first input end of the AND gate is connected to the U phase detection module, the second input end of the AND gate is connected to the V phase detection module, and the third input end of the AND gate is connected to the W phase detection module; The first input end of the NOR gate is connected to the U phase detection module, the second input end of the NOR gate is connected to the V phase detection module, and the third input end of the NOR gate is connected to the W phase detection module; The output end of the AND gate is connected to the first input end of the OR gate, the output end of the NOR gate is connected to the second input end of the OR gate, and the output end of the OR gate is respectively connected to the first input end of the AND gate and the first input end of the NOR gate; The U-phase detection module is used to detect U-phase electricity, the V-phase detection module is used to detect V-phase electricity, and the W-phase detection module is used to connect W-phase electricity.
2. The motor fault detection system according to claim 1, characterized in that: Also includes warning module; The warning module is connected to the main control module.
3. The motor fault detection system according to claim 1, characterized in that: Also includes protection modules; The protection module is connected to the main control module.
4. The motor fault detection system according to claim 1, characterized in that: Also includes a communication module; The main control module is connected to the monitoring terminal through the communication module.
5. The motor fault detection system according to claim 1, characterized in that: The circuit structures of the U-phase detection module, the V-phase detection module and the W-phase detection module are the same, and the U-phase detection module includes a current transformer L1, a diode D1, a variable resistor RP1, a capacitor C1, a resistor R1, a resistor R2, a voltage regulator D2 and an operational amplifier U1; The first end of the current transformer L1 is connected to the anode of the diode D1, the second end of the current transformer L1 is grounded, the cathode of the diode D1 is connected to the first end of the variable resistor RP1, the second end of the variable resistor RP1 is grounded, the sliding end of the variable resistor RP1 is grounded through the capacitor C1, and the sliding end of the variable resistor RP1 is connected to the non-inverting input end of the operational amplifier U1; The first end of the resistor R1 is used to connect to the VCC power supply, the second end of the resistor R1 is grounded through the resistor R2, the second end of the resistor R1 is connected to the inverting input end of the operational amplifier U1, the cathode of the voltage regulator D2 is connected to the first end of the resistor R1, the anode of the voltage regulator D2 is grounded, and the output end of the operational amplifier U1 is connected to the main control module.
6. The motor fault detection system according to claim 3, characterized in that: The protection module includes a transistor Q1 and a relay K1; The base of the transistor Q1 is connected to the main control module, the collector of the transistor Q1 is connected to the first power supply end of the relay K1, the second power supply end of the relay K1 is used to connect to the VDD power supply, and the emitter of the transistor Q1 is grounded.
7. The motor fault detection system according to claim 6, characterized in that: The protection module also includes a resistor R5, an optical coupler U2 and a resistor R4; The first end of the resistor R5 is connected to the main control module, the second end of the resistor R5 is connected to the first input end of the optocoupler U2, the second input end of the optocoupler U2 is grounded, the first output end of the optocoupler U2 is connected to the VDD power supply through the resistor R4, and the second output end of the optocoupler U2 is grounded.