Utilization of Two Sensors in Offline Diagnosis of Squirrel-Cage Rotors of Asynchronous Motors

In the manufacture squirrel-cage rotors of asynchronous motors, a high standard of quality is required in every part of the production cycle. The die casting process usually creates porosity in the rotor bars. This most common defect in the rotor often remains hidden during the entire assembly of th...

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Bibliographic Details
Published in:Energies (Basel) 2021-10, Vol.14 (20), p.6573
Main Authors: Kacor, Petr, Bernat, Petr, Moldrik, Petr
Format: Article
Language:English
Subjects:
Asynchronous motors
broken bar
Calibration
Defects
Deformation
Design
Die casting
fault detection
FEM simulation
Magnetic fields
Manufacturing
Manufacturing industry
Methods
offline diagnosis
Porosity
Production costs
Rotors
Sensors
signal processing
Squirrel cage motors
squirrel-cage
Two dimensional models
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Summary:In the manufacture squirrel-cage rotors of asynchronous motors, a high standard of quality is required in every part of the production cycle. The die casting process usually creates porosity in the rotor bars. This most common defect in the rotor often remains hidden during the entire assembly of the machine and is usually only detected during final testing of the motor, i.e., at the end of the production process. This leads to unnecessary production costs. Therefore, the aim is to conduct a continuous control immediately after the rotor has been cast before further processing. In our paper, we are interested in selecting a suitable method of offline rotor diagnostics of an asynchronous motor that would be effective for these needs. In the first step, the selection of the method and its integration into the overall manufacturing process is carried out. The arrangement of the sensors and their calibration is then simulated on a 2D Finite Element Model of the rotor. The proposed offline measurement procedures and technologies are finally validated by testing measurements on a rotor that simulates the most frequently occurring faults. A test system is also developed that provides the operator continuous information about the running rotor measurements and makes it easier to evaluate the quality of the cast rotor by means of graphical visualization of the faults.
ISSN:1996-1073
1996-1073
DOI:10.3390/en14206573