Electric Drive Current Gradient Analysis for Bending Effect Detection
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Solution Overview
Problem
Malfunctions in electric drives can lead to inaccurate current measurements and incorrect control or diagnosis, particularly in tank leakage diagnostic systems, due to issues like the bending effect or coupling clatter, which are not effectively detected by conventional methods.
Innovation Solution
A method that involves ascertaining the current flow characteristic of an electric drive unit, detecting gradient changes, and comparing them with predefined threshold ranges to establish malfunctions, allowing for the detection of mechanical issues such as the bending effect or radial oscillations, and generating a malfunction signal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional current measurement methods are used in electric drives, then the system is simple and easy to operate, but the measurement precision deteriorates due to undetected malfunctions like bending effects and coupling clatter
Solution Approach 1:
The patent applies preliminary action by establishing a baseline current flow characteristic before the malfunction occurs. The system stores reference gradient values and compares real-time measurements against this pre-established baseline, enabling early detection of deviations caused by bending effects or coupling clatter before they lead to incorrect diagnoses.
Solution Approach 2:
The patent introduces an intermediary detection layer that analyzes gradient changes in current characteristics. Instead of directly measuring the malfunction, the system uses the current gradient as an intermediate parameter that reflects the mechanical state of the drive, enabling indirect but accurate detection of bending effects and coupling issues.
2Measurement precision
If the sampling frequency is increased to detect deceleration and acceleration procedures, then the measurement precision improves, but the productivity deteriorates due to increased data processing requirements
Solution Approach 1:
The patent extracts only the essential information needed for malfunction detection by focusing specifically on gradient changes in the current characteristic. Instead of processing the entire current signal at high sampling rates, the system extracts and analyzes only the gradient parameter, significantly reducing data processing requirements while maintaining detection precision.
Solution Approach 2:
The patent applies partial action by performing gradient analysis only when necessary for malfunction detection, rather than continuously processing all current data. The system calculates gradients selectively to identify deceleration and acceleration procedures, reducing overall computational load while maintaining adequate measurement precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables reliable detection of malfunctions in electric drives, preventing incorrect diagnoses and allowing for the classification of defective components, thereby ensuring accurate tank leakage diagnostic procedures.
Implementation Method 1
capture the current that is supplied to the motor and to use said current by way of example for controlling the drive
Implementation Method 2
a rotor is decelerated and accelerated and these procedures are transmitted to the electric drive unit. The bending effect can cause 'bends' in the current flow characteristic
Implementation Method 3
a so-called coupling clatter can occur as a result of the rigidity of the coupling of the two components and in defined frequency ranges this clatter can influence the current measurement
Implementation Method 4
the play in the rotor on the drive shaft of the rotor can cause oscillations in the radial direction. If the magnitude of the oscillation is in the resonance range, then this additional energy requirement leads to a deceleration of the electric motor
Data Source
AI summary
A method and a corresponding system for detecting a malfunction in an electric drive unit. The method comprises the following steps: ascertain (S17) a current flow characteristic (1) of an electric drive unit; detect (S33) a gradient change in the current flow characteristic (1) at a first point in time (t=n); compare (S35, S39) the gradient change with a predefinable gradient change range; establish (S45) a malfunction in the electric drive unit if the gradient change is outside the predefinable gradient change range.