Non-Contact Voltage and Current Sensor for Motor Diagnosis
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Solution Overview
Problem
Existing diagnostic devices for mechanical systems driven by electric motors cannot accurately diagnose sluggishness and its causes due to reliance on empirical assumptions and lack of precise measurement of current and voltage curves, especially in environments requiring non-reactive and potential-free conditions.
Innovation Solution
The use of non-contact sensors to detect electric fields in conductors, along with Hall sensors for current measurements, provides a precise and independent measurement of voltage and current curves, allowing for accurate diagnosis and eliminating the need for external reference potentials, enabling operation in potential-free environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact-based voltage measurement is used, then voltage can be measured against a reference potential, but the measurement cannot be performed in potential-free environments and may interfere with existing wiring
Solution Approach 1:
The patent replaces contact-based voltage measurement with contactless electric field sensing using sensors that detect the electric field generated by voltage in conductors. This substitution eliminates the need for physical contact with conductors and reference potentials, enabling measurement in potential-free environments while maintaining measurement capability through field detection rather than direct electrical connection
Solution Approach 2:
The patent introduces electric field sensors as an intermediary between the voltage source and the measurement system. These sensors detect the electric field surrounding conductors without requiring direct electrical contact, serving as a mediator that transfers information about voltage levels without establishing an electrical connection that would require reference potentials or interfere with existing wiring
2Reliability
If current curves are measured over time, then mechanical stiffness development can be detected, but precise segmentation of mechanical processes and identification of stiffness causes is difficult
Solution Approach 1:
The patent segments the continuous current curve measurement into discrete mechanical process phases by detecting characteristic points such as start and end positions of mechanical components. This segmentation is achieved by analyzing the current waveform for specific patterns that correspond to mechanical events, allowing the continuous measurement to be divided into meaningful segments that can be individually analyzed for stiffness detection and localization
Solution Approach 2:
The patent performs preliminary identification of mechanical process phases and characteristic points in the current curve before conducting detailed stiffness analysis. By first detecting and marking key events such as start positions, end positions, and transition points in the mechanical cycle, the system prepares the data structure necessary for subsequent precise segmentation and cause-specific diagnosis of mechanical stiffness
3Device complexity
If empirical assumptions are used for diagnosis, then diagnostic devices can be simpler, but diagnostic accuracy for sluggishness and its causes is reduced
Solution Approach 1:
The patent implements feedback by continuously comparing measured current and voltage waveforms against expected patterns for different mechanical states. The system uses the measured data to update its understanding of mechanical condition in real-time, adjusting its diagnosis based on actual measurements rather than relying solely on pre-programmed empirical assumptions. This feedback mechanism maintains diagnostic accuracy while allowing the system to adapt to specific installation conditions
Solution Approach 2:
The patent enables the diagnostic system to self-calibrate and self-adjust by using its own measurements to refine its diagnostic models. The system automatically identifies characteristic patterns in the measured waveforms and uses these to improve its diagnostic accuracy over time without requiring external calibration or adjustment, reducing reliance on manufacturer-specific empirical assumptions while maintaining simplicity
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 allows for precise segmentation of mechanical processes, improved detection of mechanical sluggishness, and efficient maintenance by providing detailed current and voltage curve analysis, reducing maintenance costs and improving diagnostic accuracy.
Implementation Method 1
Hall sensors (4.1, 4.2, 4.3) are attached to each individual conductor (1, 2, 3) to measure the current flow in the respective conductor
Implementation Method 2
sensors (5.1, 5.2, 5.3) are attached to each individual conductor (1, 2, 3) to measure the electric field of the conductor and thus measure the voltage flow in the respective conductor
Data Source
Figure 1
AI summary
The invention relates to a device for diagnosing a mechanical system which is driven by means of an electric drive motor, the drive motor thereof, and the shifting device thereof, comprising at least one sensor for detecting the current curve in a conductor (1, 2, 3) of the electric connection of the drive motor. The precision and the degree of detail of the diagnosis are to be improved compared to the prior art and expanded to include the drive motor and the shifting device in order to improve the efficiency and aim of the maintenance process carried out in response to the diagnosis. According to the invention, this is achieved in that the device additionally has sensors for detecting the voltage curves in the conductors of the electric connection of the drive motor, wherein each conductor (1, 2, 3) is paired with a sensor (4.1, 4.2, 4.3) for detecting the current curve and with a sensor (5.1, 5.2, 5.3) in interaction with a sensor (6) in order to detect the voltage curve.