System and method for detection of motor vibration

• US 9,673,685 B2
• Filed: 04/02/2014
• Issued: 06/06/2017
• Est. Priority Date: 04/02/2014
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Yuan, Zhenhuan, Ramanarayanan, Shankernarayan, Sawant, Manas, Qian, Wei, Cooper, Mark, Bronk, Kelly J., Feng, Shun, Schmidt, Robert H.
• Primary Examiner(s): GLASS, ERICK DAVID
• Application Number:
  US14/243,353
• Publication Number:
  US 20150288257A1
• Time in Patent Office: 1,161 Days
• Field of Search: 318460
• CPC Class Codes: G01M 1/14 Determining imbalance G01M1/30 takes precedence
• CPC Class Codes: H02K 11/20 for measuring, monitoring, testing, protecting or switching rectifiers H02K11/04; power electronics H02K11/33
• CPC Class Codes: H02K 5/24 specially adapted for suppression or reduction of noise or vibrations
• CPC Class Codes: H02P 21/14 Estimation or adaptation of machine parameters, e.g. flux, current or voltage

Abstract

An improved system for monitoring vibration of an electric machine is disclosed. According to one embodiment, sensors are positioned in a plane orthogonal to the motor shaft and each sensor detects vibration along at least one axis of the motor. The sensors are oriented such that the polarity of each sensor is reversed. The pairs of sensors may be used to isolate specific vibrations within the motor. According to another embodiment, a sensor may be mounted directly to the motor shaft. The sensor on the motor shaft directly detects vibrations along the motor shaft. Optionally, a second sensor may be mounted to a fixed location within the motor housing, and the combination of the sensor on the motor shaft and the sensor at a fixed location may be used to isolate specific vibrations within the motor. A motor controller may adjust operation of the motor to reduce the isolated vibration.

Claims

1. An electric machine configured to be operated by a controller, the electric machine comprising:

a housing;

a stator mounted within the housing and configured to receive a voltage from the controller to control operation of the electric machine;

a rotor rotatably mounted within the housing, wherein the rotor rotates as a function of the voltage applied to the stator;

a shaft connected to the rotor and extending outside the housing, the shaft having a central axis about which it rotates;

a first sensor mounted at a first position proximate to the shaft and configured to generate a signal corresponding to a vibration detected at the first position; and

a second sensor mounted at a second position proximate to the shaft and configured to generate a signal corresponding to a vibration detected at the second position, wherein;

the first position and the second position are located in a plane orthogonal to the central axis of the shaft,

the signals corresponding to the vibration detected at the first and second positions are transmitted to the controller,

the controller adjusts operation of the voltage provided to the stator as a function of the signals corresponding to the vibration detected at the first and second positions to reduce a magnitude of the vibration,

the vibration detected at the first position by the first sensor is in a first axis,

the first axis is oriented either tangentially to a rotation of the shaft or parallel to the central axis of the shaft,

the vibration detected at the second position by the second sensor is in a second axis, and

the second axis is located on an opposite side of the shaft and is oriented either tangentially to a rotation of the shaft or parallel to the central axis of the shaft.

2. The electric machine of claim 1 wherein the signal generated by the first sensor has a first polarity and the signal generated by the second sensor has a second polarity, wherein the first polarity is opposite the second polarity.

3. The electric machine of claim 1 wherein:

the first sensor measures vibration in a first set of axes and generates a plurality of first vibration signals, each first vibration signal corresponds to a magnitude of vibration detected at the first position and measured in one axis of the first set of axes, wherein each of the first vibration signals corresponds to a vibration measured in a different axis than the other first vibration signals,

the second sensor measures vibration in a second set of axes and generates a plurality of second vibration signals, each second vibration signal corresponds to a magnitude of vibration detected at the second position and measured in one axis of the second set of axes, wherein each of the second vibration signals corresponds to a vibration measured in a different axis than the other second vibration signals, and

each axis of the first vibration signals corresponds to one axis of the second vibration signals.

4. The electric machine of claim 3 wherein each of the plurality of first vibration signals has a first polarity and each of the plurality of second vibration signals has a second polarity, wherein the first polarity of each of the first vibration signals is opposite the second polarity of the corresponding second vibration signal.

5. The electric machine of claim 1 further comprising:

a third sensor mounted at a third position proximate to the shaft and configured to generate a signal corresponding to a vibration detected at the third position; and

a fourth sensor mounted at a fourth position proximate to the shaft and configured to generate a signal corresponding to a vibration detected at the fourth position, wherein the third position and the fourth position are located in a plane orthogonal to the central axis of the shaft, the signals corresponding to the vibration detected at the third and fourth positions are transmitted to the controller, and the controller further adjusts the voltage provided to the stator of the electric machine as a function of the signals corresponding to the vibration detected at the third and fourth positions.

6. The electric machine of claim 1 wherein the first position is located on the shaft and the second position is a fixed mounting point.

7. An electric machine configured to be operated by a controller, the electric machine comprising:

a housing;

a stator mounted within the housing and configured to receive a voltage from the controller to control operation of the electric machine;

a rotor rotatably mounted within the housing, wherein the rotor rotates about a central axis as a function of the voltage applied to the stator;

at least two sensors, each sensor mounted at a position proximate to the rotor and each sensor configured to generate a signal corresponding to a vibration detected at the position the sensor is mounted, wherein;

each position is located in a plane orthogonal to the central axis,

each signal is transmitted to the controller,

the controller identifies a first vibration and a second vibration as a function of the signals corresponding to the vibration detected, wherein the first vibration identified is a different vibration than the second vibration identified and each of the first and second vibrations are selected from one of a rotational vibration, a radial unidirectional vibration, an axial directional vibration, a mechanical resonance, and a motor inclination, and

the voltage received at the stator from the controller is varied as a function of the type of vibration identified to reduce the identified vibration.

8. The electric machine of claim 7 further comprising a shaft coupled to the rotor wherein one of the at least one sensors is mounted to the shaft.

9. The electric machine of claim 8 wherein one of the at least one sensors is mounted at a fixed location within the housing proximate to the shaft.

10. The electric machine of claim 7 wherein:

the at least two sensors includes a first sensor mounted at a first position,

the vibration detected at the first position by the first sensor is in a first axis,

the first axis is oriented either tangentially to a rotation of a shaft connected to the rotor or parallel to the central axis of the shaft,

the at least two sensors include a second sensor mounted at a second position,

the vibration detected at the second position by the second sensor is in a second axis, and

the second axis is oriented either tangentially to a rotation of the shaft or parallel to the central axis of the shaft.

11. The electric machine of claim 10 further comprising at least one bearing set configured to rotatably mount the rotor within the housing wherein the first position and the second position are selected proximate to the bearing set.

12. The electric machine of claim 10 wherein:

the first sensor measures vibration in a first set of axes and generates a plurality of first vibration signals, each first vibration signal corresponds to a magnitude of vibration detected at the first position and measured in one axis of the first set of axes, wherein each of the first vibration signals corresponds to a vibration measured in a different axis than the other first vibration signals,

the second sensor measures vibration in a second set of axes and generates a plurality of second vibration signals, each second vibration signal corresponds to a magnitude of vibration detected at the second position and measured in one axis of the second, set of axes, wherein each of the second vibration signals corresponds to a vibration measured in a different axis than the other second vibration signals, and

each axis of the first vibration signals corresponds to one axis of the second vibration signals.

13. The electric machine of claim 10 wherein the at least two sensors further includes a third sensor mounted at a third position and a fourth sensor mounted at a fourth position, wherein the third position and the fourth position are located in a plane orthogonal to the central axis of the shaft, each signal generated from the third and fourth sensor is transmitted to the controller, and the controller further adjusts the voltage received at the stator from the controller as a function of the signals corresponding to the vibration detected at the third and fourth positions.

14. A method of controlling operation of an electric machine, the method comprising the steps of:

generating a voltage with a controller, wherein the voltage is provided to a stator of the electric machine, which, in turn, causes rotation of a rotor of the electric machine;

generating a signal responsive to a vibration along a first axis present at a first position within the electric machine with a first sensor mounted at the first position wherein the signal generated by the first sensor has a positive magnitude and a negative magnitude and wherein the first axis is oriented either tangentially to a rotation of a shaft connected to the rotor or parallel to the central axis of the shaft;

transmitting the signal corresponding to the vibration present at the first position from the first sensor to the controller;

generating a signal responsive to a vibration along a second axis present at a second position within the electric machine with a second sensor mounted at the second position wherein;

the signal generated by the second sensor has a positive magnitude and a negative magnitude,

the positive magnitude of the first sensor is in the same direction as the negative magnitude of the second sensor,

the first position and the second position are located in a plane orthogonal to a shaft of the electric machine, and

the second axis is oriented either tangentially to a rotation of the shaft or parallel to the central axis of the shaft;

transmitting the signal corresponding to the vibration present at the second position from the second sensor to the controller; and

adjusting the voltage provided to the stator with the controller as a function of the signals corresponding to the vibration present at the first and second positions to reduce a magnitude of the vibration.

15. The method of claim 14 wherein:

the first sensor measures vibration in a first set of axes and generates a plurality of first vibration signals, each first vibration signal corresponds to a magnitude of vibration detected at the first position and measured in one axis of the first set of axes, wherein each of the first vibration signals corresponds to a vibration measured in a different axis than the other first vibration signals,

the second sensor measures vibration in a second set of axes and generates a plurality of second vibration signals, each second vibration signal corresponds to a magnitude of vibration detected at the second position and measured in one axis of the second set of axes, wherein each of the second vibration signals corresponds to a vibration measured in a different axis than the other second vibration signals, and

each axis of the first vibration signals corresponds to one axis of the second vibration signals.

16. The method of claim 15 wherein each of the plurality of first vibration signals has a first polarity and each of the plurality of second vibration signals has a second polarity wherein the first polarity of each of the first vibration signals is opposite the second polarity of the corresponding second vibration signal.

17. The method of claim 14 further comprising the steps of:

detecting a vibration present at a third position within the electric machine with a third sensor mounted at the third position;

transmitting a signal corresponding to the vibration present at the third position from the third sensor to the controller;

detecting a vibration present at a fourth position within the electric machine with a fourth sensor mounted at the fourth position, wherein the third position and the fourth position are located in a plane orthogonal to the shaft of the electric machine; and

transmitting a signal corresponding to the vibration present at the fourth position from the fourth sensor to the controller, wherein the controller further adjusts the voltage provided to the stator as a function of the signals corresponding to the vibration detected at the third and fourth positions.