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Vibration Analysis of the Electric Drive System with Inter-turn Short-Circuit and Gear Spalling Faults

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Abstract

Introduction

The electric drive system is usually composed of an electric motor and gear transmission system, and widely used for industrial applications. However, the dynamic behaviors of the coupled electromechanical system are still not well understood, especially when there are faults in the system.

Purpose

The faults such as gear spalling fault of the mechanical system or inter-turn short-circuit fault of electrical device will threaten the operation safety of the electric vehicle. Thus, the faulty dynamic analysis for the electric drive system is crucial for avoiding fatal catastrophes.

Method

In this paper, the permeance network motor model with inter-turn short-circuit fault and the dynamic planetary gear transmission model considering spalling faults are proposed, respectively. The electromechanical dynamic model integrating two models mentioned above is employed to acquire the fault characteristics. Then, the vibration characteristics of the electric drive system with and without gear fault or inter-turn fault under the effects of time-varying mesh stiffness, slot effect and magnetic saturation are distinguished at different operation conditions.

Results

The results show that the inter-turn short-circuit fault can trigger conspicuous harmonics within the low frequency domain of the mesh force components, which will predicatively obstruct the detection or diagnosis of the spalling fault. Moreover, the vibration characteristics and vibration mechanism concerning these faults are revealed by the frequency and statistical analysis, which facilitates the condition monitoring for the gear transmission system when the tooth spalling and inter-turn faults are coupled.

Conclusion

The research results bring theoretical reference for the dynamic analysis and vibration-based condition monitoring of the vehicles’ integrated electric drive system.

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Data availability

The data that support the findings of this study are available within the article or from the corresponding author, upon reasonable request.

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Acknowledgements

This research was funded by the National Natural Science Foundation of China (Grant No. 52105127), the Natural Science Foundation of Zhejiang Province (Grant No. LGG22E050025), the Open Foundation of State Key Laboratory of Mechanical Transmission, P. R. China (Grant No. SKLMT-MSKFKT-202112). The authors declare no conflict of interest, and, are thankful for the advice and recommendation of the reviewers and editors.

Funding

The National Natural Science Foundation of China (Grant no. 52105127); Natural Science Foundation of Zhejiang Province (Grant no. LGG22E050025); Open Foundation of State Key Laboratory of Mechanical Transmission (Grant no. SKLMT-MSKFKT-202112).

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Authors and Affiliations

  1. Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education, Zhejiang University of Technology, Hangzhou, 310023, People’s Republic of China

    Wenyu Bai, Xuanyi Zhou, **a Hua & Guanjun Bao

  2. Zhejiang **bang Sports Equipment Co., Ltd., No. 1 Juxian Road, Huzhen Town, **yun County, Zhejiang, 321404, People’s Republic of China

    Wenyu Bai

  3. University of Texas at Arlington, Arlington, TX, 76019, USA

    Yawen Wang

  4. The State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing, 400030, People’s Republic of China

    Qiang Zeng & Sen Zhan

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  1. Wenyu Bai
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Correspondence to Xuanyi Zhou.

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Bai, W., Zhou, X., Wang, Y. et al. Vibration Analysis of the Electric Drive System with Inter-turn Short-Circuit and Gear Spalling Faults. J. Vib. Eng. Technol. 11, 3595–3605 (2023). https://doi.org/10.1007/s42417-022-00770-y

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