EOMYS ENGINEERING

Noise and vibration Dynamic Signal Analysis on electrical machines

15/04/2015
LE BESNERAIS Jean
SOURON Quentin
www.eomys.com

EOMYS ENGINEERING 2014-2015

A. EOMYS ENGINEERING
B. Why Dewesoft ?
C. Magnetic acoustic noise and vibrations in electrical machines
D. Measurement set-up
E. Acquisition software set-up
F. Post-processings
G. Conclusion

EOMYS ENGINEERING 2014-2015

(C) EOMYS
ENGINEERING 2013-2014

A. EOMYS ENGINEERING
Overview

Young Innovative Company* created in may 2013

Located in Lille, North of France

Activities : engineering consultancy & applied research

specialized in electrical engineering

Sectors : transportation (railway, automotive, marine,

aeronautics), energy (wind, hydro), industry

*"Jeune Entreprise Innovante": the French government recognises that EOMYS runs significant R&D activities
EOMYS ENGINEERING 2014-2015

Services
Analyze and solve your multi-physics technical issues

multiphysics experiments (investigation, pre-certification) and simulations

advanced post-processings of experimental and simulation data
sensitivity studies, technical state of the art
proposal of technical solutions and validation by tests or simulation

Improve your design process performance

development, validation and integration of high performance models

development of user-specific design interfaces
formalization of design rules
delivery of high-level technical trainings

Optimize your products and processes

coupling with multiobjective constrained optimization methods

automation of the design process
optimization of the virtual prototyping chain

Innovate

technical state of the art, ideation, concept ranking and validation

research consortium / co-development projects
licence granting
EOMYS ENGINEERING 2014-2015

MANATEE software

fast electromagnetic and vibro-acoustic simulation of electrical machines (Matlab-based)

use of analytical, semi analytical and numerical models to reach the best compromise accuracy / speed
automated coupling with FEMM (electromagnetic) and GetDP (mechanics)
modeling of all space and time harmonics
fault simulation (e.g. eccentricity, broken bar, demagnetization)
more than 100 post processing graphs

see more at www.eomys.com

EOMYS ENGINEERING 2014-2015

EOMYS
ENGINEERING 121, rue de Chanzy 59260 Lille-Hellemmes
FRANCE

Experience
Optimal design of innovative systems
permanent magnet synchronous wind generators, traction induction machines
transformers and inductors

Scientific software development

use of open sources (FEMM, GetDP, OpenFoam, Octave) & commercial software (Flux, Opera, Ansys, Matlab)
advanced optimization methods (multiobjective constrained genetic algorithms, space-mapping)
development and distribution of MANATEE software

Analytical, semi-analytical and numerical modelling

CFD simulation coupled to thermal nodal networks, hydraulic networks
electromagnetic subdomain models, reluctance network models
structural beam element models

Experimental characterization
noise and vibration measurements
thermal and electrical measurements

EOMYS ENGINEERING 2014-2015

Internal R&D programme

Reduction of noise & vibration in electrotechnical systems
active and passive techniques in rotating electrical machines and passive components
3D electro-vibro-acoustic simulation of rotating machines (asymmetries, skewing)
modeling of magnetic forces in rotating machines
magnetostriction and Maxwell force simulation (GetDP)
development of hybrid simulation methods (FEM / semi-analytic)

Experimental vibroacoustic characterization

advanced post processings
new measuring methods of structural modes and operational deflection shapes

EOMYS ENGINEERING 2014-2015

EOMYS
ENGINEERING 121, rue de Chanzy 59260 Lille-Hellemmes
FRANCE

B. WHY DEWESOFT ?

A multiphysic acquisition software suitable for multiphysics consulting activities of EOMYS (electrical
engineering, thermics, vibro-acoustics, etc.)

A flexible software suitable for both investigation tests and pre-certification tests

An acquisition system suitable for both low frequency (ex: temperature) and high frequency (ex: noise)

A light-weight acquisition module suitable for field measurements

A cost-competitive solution

EOMYS ENGINEERING 2014-2015

C. MAGNETIC NOISE AND VIBRATIONS IN ELECTRICAL MACHINES

What do we call electromagnetic acoustic noise or electrical noise ?

Sinusoidally-fed squirrel cage induction machine during run-up ( slotting noise )

Non-sinusoidally-fed squirrel cage induction machine at starting ( PWM noise )

-> high frequency (100 to 10000 Hz), high tonality noise

Definition

Magnetic noise and vibrations is defined as noise and vibrations due to magnetic forces

Magnetic forces can be defined as forces arising from the presence of a magnetic field
-> magnetic noise stops when an induction machine is current-free

Two magnetic forces exist in electrical machines: magnetostriction & Maxwell forces

EOMYS ENGINEERING 2014-2015

Magnetostriction forces tend to

shrink the iron along the field lines

Maxwell forces tend to get the

stator closer to the rotor

STATOR
yoke

ROTOR
slots
teeth
from [B7]

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Electrical noise and vibration phenomena

electrical machine
endplate

mount

Tangential and radial magnetic force harmonics generate radial

vibrations propagating to the external frame

Torque harmonics can propagate through rotor shaft as

torsional vibrations, and efficiently radiated (large surface /
normal vibrations) like gearbox frame or mount

Unbalance forces harmonics generate shaft bending vibrations

which propagate to bearing & frame

Axial forces make endplates axial vibrations

Forced excitation + resonances

gearbox

frame

shaft
supports

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Why do electrical noise and vibrations matter ?

Health (e.g. in industry): lower the exposure to acoustic noise level

Comfort (e.g. in transportation): increase the sound pleasantness based on psychoacoustic metrics

Security (e.g. in defense): lower the vibroacoustic signature

Robustness (e.g. in energy): lower the electromechanical fatigue

Standard requirements

Electromagnetics & vibroacoustics interactions

Cost optimization -> thinner yoker -> increased vibration & noise

Skewing technique which is used to reduce noise and vibration levels degrades torque and efficiency

Electromagnetic & thermal & vibro-acoustic design have therefore strong interactions

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Characterization of electrical noise and vibration

time frequency f

space frequency = space order = wavenumber r

r=0

r=6

harmonic origin: slotting, winding, PWM, saturation, eccentricity

wave type: pulsating Vs rotating, rotation direction

forced excitation Vs resonance

largest magnetic force occurs at f=2fs (electrical frequency) r=2p (pole pair number)

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D. MEASUREMENT SETSET-UP

Dewetron SIRIUS 8 channel ACC+

B&K 1-axis radial accelerometer in the middle of the stator stack

(at least 8 recommended to capture r=4 order)

PCB free field microphone 1 m away from the outer frame

Optel Thevon tachometer (1 pulse per rev)

Chauvin Arnoux current clamps

ACTIVE

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E. ACQUISITION SETSET-UP
Spectrograms

FFTs for noise (20 kHz), accelerometers (10 kHz) and current (5 kHz)

Tachometer setup

Analog tacho

Order tracking

For magnetic vibrations due to slotting effects the best orders to be tracked are 2p, Zr-2p, Zr, Zr+2p (p:
number of pole pairs, Zr: number of rotor slots or number of rotor poles)

-> some high rank orders are needed for high torque machines (ex: Zr=212)

For mechanical vibrations the order 1 should be also tracked

Specific set-ups are used for the best tradeoff between rpm and Hz accuracy

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 EOMYS ENGINEERING 2014-2015

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Operation Deflection Shape

Use of modal test environment of Dewesoft to visualize the stator deflection under magnetic forces

Calculation of reverberation time

Use of Dewesoft + Matlab to obtain the reverberation time in order to estimate the direct field (electrical
machine) and indirect field (room reflections) contribution to the overall sound pressure level

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A-weighting and third octave analysis

dB and dBA as a function of speed

Other tips

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Normalization of the noise level to the current level

Online estimation of slip in asynchronous machines using tracking filter

Current angle calculation based on 2 or 3 phase measurements

Spatiograms: 2D FFT run-ups of circumferential vibration waves

EOMYS ENGINEERING 2014-2015

( )
=1

60

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F. EXPERIMENTAL RESULTS
Operation deflection shape (case of a 1MW induction machine, r=1 & 2)

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Current spectrograms (IM, raw)

fundamental

EOMYS ENGINEERING 2014-2015

slotting harmonic with dynamic

rotor motion

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Case of a concentrated winding PM synchronous machine (12 stator slots, 10 poles)

run-up to 2200 rpm

switching frequency at 1500 Hz

8 accelerometers

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Accelerometer spectrograms (raw)

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slotting excitations
Accelerometer spectrograms (run(run-up)

PWM +slotting excitations

PWM excitations

natural frequencies (vertical lines)

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Zoom on slotting excitations matching a mode close to 250 Hz

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Order tracking

EOMYS ENGINEERING 2014-2015

Wavenumber r=2
modulated by
eccentricity

250 Hz natural frequency (parabola)

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Spatiogram:
Spatiogram: spectrogram of a specific space order r
Complex value + dual side FFT

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r=2, f=2fs
Spatiogram r=2

r=2p=10, f=-fswi -2fs

same as r=-10, f=fswi +2fs

r=2p=+10, f=fswi -2fs

not available yet as a function of rpm

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r=-2 and +2 spatiograms are the same (transposition)

r=2

r=-2

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r=0

r=2

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Sidebands due to eccentricities

Mechanical unbalance (rotation frequency)

r=1

First bending mode

r=2

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r=3

r=2

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r=4

r=2

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Plot / slot interactions appear as single sided-excitation (pure rotating force waves)

Eccentricities and PWM vibrations appear as double sided excitations (modulation effects: pairs of travelling
vibration waves)

Natural frequencies appear as symmetrical amplifications in double sided FFTs

The machine vibration behavior is determined by wavenumbers 1 and 2

Spatiograms based on Dewesoft Math functions are far more efficient than doing an ODS at each
frequency and each speed

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G. CONCLUSIONS

Advanced rotating machine analysis applied to electrical noise & vibrations reduction

On field post-processings allow to quickly identify the physical origin of noise & vibration

Combined with internal simulations (e.g. MANATEE software) some mechanical and electromagnetic
redesign possibilities can be proposed and validated

Up to 15 dB reduction has been obtained after redesign

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Thank you for your attention

Any questions?
questions?
www.eomys.com

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