Electromechanical Machine Temperature Monitoring Without Rotor Sensors
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Solution Overview
Problem
Monitoring the temperature of critical components in electromechanical machines, especially in high-power applications, is challenging due to the complexity of installing sensors on rotors and the need for extensive historical data for accurate temperature estimation.
Innovation Solution
A method and machine controller that utilize electrical and mechanical simulation models to estimate temperature distributions based on structural and operating data, eliminating the need for direct sensor installation by simulating electrical and mechanical energy losses and adjusting conductivity values, allowing for real-time temperature monitoring and regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are installed on the rotor to directly measure temperature, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent creates a virtual copy of the physical temperature measurement system by developing a thermal simulation model that replicates temperature distribution in the rotor. Instead of installing physical sensors on the rotor, the system uses electrical operating data and thermal models to generate virtual temperature measurements, eliminating the need for complex sensor installation while maintaining measurement capability
Solution Approach 2:
The patent replaces the mechanical/physical sensor installation system with an electrical computation system. By substituting physical temperature sensors with electrical operating data processing and thermal simulation, the system eliminates the need for mechanical sensor mounting on the rotor while achieving temperature monitoring through computational methods
2Device complexity
If historical operating data are used to estimate temperatures, then device complexity is reduced, but measurement precision deteriorates due to insufficient data requirements
Solution Approach 1:
The patent performs preliminary actions by pre-processing electrical operating data and pre-calibrating the thermal simulation model before actual temperature monitoring begins. The system prepares the computational framework in advance, storing necessary electrical parameters and establishing the thermal model relationships, so that during operation, temperature estimation can be performed accurately without requiring extensive historical data collection
Solution Approach 2:
The patent transforms the input parameters from requiring extensive historical temperature data to using electrical operating data (current, voltage, power). By changing the parameter basis from thermal-historical to electrical-real-time, the system achieves both reduced complexity and maintained precision through the relationship between electrical inputs and thermal outputs defined by the simulation model
3Device complexity
If temperature sensors are installed at easily accessible points, then device complexity is reduced, but measurement precision deteriorates for inaccessible components
Solution Approach 1:
The patent transitions from point-based temperature measurement (single location) to field-based temperature distribution measurement (spatial dimension). By using thermal simulation models that compute temperature across the entire rotor volume rather than at single sensor points, the system achieves temperature information for inaccessible internal components without additional physical sensors
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 approach enables efficient and accurate temperature monitoring of hard-to-reach components without additional hardware, reducing wear and increasing the service life of machines by using available operating data and machine learning models for improved simulation accuracy.
Implementation Method 1
electrical energy losses in the machine are continuously simulated in a spatially resolved manner using an electrical simulation model of the machine
Implementation Method 2
a temperature distribution in the machine is continuously simulated using a thermal simulation model of the machine
Data Source
AI summary
In order to monitor the temperature of an electromechanical machine using electrical operating data of the machine, structural data concerning a geometry, a thermal conductivity and an electrical conductivity of elements of the machine is imported. Using the structural data and the electrical operating data, electrical energy losses in the machine are continuously simulated in a spatially resolved manner by means of an electrical simulation model of the machine. Furthermore, a temperature distribution in the machine is continuously simulated by means of a thermal simulation model of the machine using the structural data and the simulated electrical energy losses. In accordance with the simulated temperature distribution, a temperature value is then determined for a component of the machine and output in order to monitor its temperature.