System and method for predicting mechanical failures in machinery driven by an induction motor

A system for detecting mechanical disturbances in machinery driven by an induction motor, said system comprising:

• a current sensor monitoring current in at least one phase of the motor and transmitting a corresponding current signal;
• a voltage sensor monitoring voltage in said chase of the motor and transmitting a corresponding voltage signal;
• a pulse generator receiving said current and voltage signals and transmitting a pulsed signal comprising pulses having leading and trailing edges corresponding to changes in polarity of said current and voltage signals;
• a processor receiving and processing said pulsed signal to determine motor torque;
• a coordinates subprocessor for transforming motor torque values from time to rotor-angle-dependent coordinates;
• and
• a fractal generator for displaying motor torque values in rotor angle dependent coordinates obtained from said coordinates subprocessor.

A method for detecting mechanical disturbances in machinery driven by an induction motor, said method comprising:

• monitoring torque of the motor during operation of the machinery;
• developing an operating profile of motor torque reflecting motor torque during operation of the machinery;
• comparing the operating profile to a reference profile of motor torque reflecting motor torque during normal operation of the machinery to identify a deviation, said comparing comprising electronic signal processing of motor torque in relation to a phase angle of the motor, said electronic signal processing comprising performing a Fast Fourier Transform analysis of a phase angle time series and decomposing the motor torque frequency spectrum to identify diagnostically informative spectrum components;
• and
• signaling a mechanical failure of the machinery responsive to identification of said deviation.

A method for detecting mechanical failures in machinery driven by an induction motor, said method comprising:

• determining motor torque for a plurality of angular positions of a rotor;
• creating an experimental fractal representing a current state of the monitored machinery, said experimental fractal relating a plurality of torque values to said plurality of angular positions of said rotor;
• and
• displaying said experimental fractal to permit a visual analysis.

A method for detecting mechanical disturbances in machinery driven by an induction motor, said method comprising:

• monitoring torque of the motor during operation of the machinery;
• developing an operating profile of motor torque reflecting motor torque during operation of the machinery;
• comparing the operating profile to a reference profile of motor torque reflecting motor torque during normal operation of the machinery to identify a deviation, said comparing comprising evaluating Fast Fourier Transform and experimental fractal diagnostic indicators;
• and
• signaling a mechanical failure of the machinery responsive to identification of said deviation.