Non-invasive Motor Rubbing Detection via Stator Conductors
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Solution Overview
Problem
Conventional rubbing detection methods in motors are invasive, requiring motors to be stopped and disassembled, and are slow to detect rubbing, often only identifying damage after it has occurred, which can lead to machinery degradation and malfunction.
Innovation Solution
A non-invasive rubbing detection technique using electrical conductors placed on motor components, such as stators, to detect rubbing by monitoring electrical continuity, allowing for real-time detection and quantification of rubbing without disrupting motor operation, using conductors that can be disposed on, flush with, or embedded in the stator surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional rubbing detection methods are used, then rubbing can be detected, but the motor must be stopped and disassembled, resulting in loss of time and reduced productivity
Solution Approach 1:
Electrical conductors are pre-installed on stator components during manufacturing, positioned to be worn away by rubbing contact with the rotor. This preliminary placement enables continuous monitoring without requiring future disassembly, resolving the contradiction between detection accuracy and time loss.
Solution Approach 2:
The patent replaces mechanical inspection methods (disassembly and physical examination) with an electrical monitoring system. Electrical conductors provide continuous rubbing detection through electrical continuity measurements, eliminating the need for mechanical disassembly and reducing motor downtime while maintaining detection accuracy.
2Measurement precision
If conventional rubbing detection methods are used, then rubbing can be detected, but detection occurs only after damage has occurred, reducing reliability
Solution Approach 1:
Electrical conductors are installed in advance on stator surfaces where rubbing is likely to occur. These conductors serve as early warning indicators that detect rubbing contact before it causes significant damage to motor components, thereby improving both detection timing and operational reliability.
Solution Approach 2:
The electrical conductors on the stator self-monitor for rubbing contact through their electrical properties. When rubbing occurs, the conductors are worn away, changing their electrical continuity or resistance characteristics, providing automatic early detection without external intervention and improving reliability.
3Measurement precision
If invasive detection methods are used, then rubbing can be detected, but the procedure is complex and requires disassembly, increasing device complexity
Solution Approach 1:
The electrical conductors serve multiple functions: they are part of the stator's electrical structure and simultaneously serve as rubbing detection sensors. This multi-functionality eliminates the need for separate detection devices, reducing overall system complexity while maintaining detection capability.
Solution Approach 2:
The stator's existing electrical conductors are utilized for dual purposes: their primary electrical function and their secondary function as rubbing detection sensors. The conductors self-monitor their own condition through electrical continuity measurements, eliminating the need for complex external detection systems.
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
Enables early detection of rubbing, preventing malfunction and allowing for proactive maintenance, reducing the need for invasive procedures and extending the lifespan of motor components by identifying wear before it causes damage.
Implementation Method 1
providing an electrical conductor on a surface of a motor component. The electrical conductor has a first end and a second end. The electrical connection is determined by probing the first end and the second end to determine whether there is an electrical connection across the electrical conductor
Data Source
AI summary
Non-invasive rubbing detection for motors is disclosed. In an embodiment, a method of detecting rubbing on a stator of a motor includes providing an electrical conductor on the stator, (the electrical conductor has a first end and a second end). The method further includes determining that there is rubbing on a surface of the stator, including by probing the first end and the second end to determine whether there is an electrical connection across the electrical conductor, and determining that there is rubbing on the stator if there is no electrical connection. In an embodiment, the electrical conductor is disposed on the surface of the stator by etching away conductive foil to form the electrical conductor, and providing the electrical conductor.