Modeling of Synchronous Machines with Damper Windings for Condition Monitoring

Mina M. Rahimian
Student Member, IEEE

Karen Butler-Purry
Senior Member, IEEE

Department of Electrical and Computer Engineering Texas A&M University College Station, Texas 77843-3128 E-mail: Rahimian@ece.tamu.edu
Abstract- In this paper, a method of modeling synchronous machines with damper windings based on the winding function approach (WFA) has been proposed. This method of machine analysis with the actual winding distribution does not require neglecting the harmonics of the winding distributions. The proposed model can be used to simulate the machine under faulty conditions such as broken damper bars and end ring, eccentricities and inter-turn faults. Given the geometry of the machine and its winding configuration, all the inductances are calculated as a function of the rotor position. The skewed rotor is included in the model and its smoothing effects on the waveforms are presented. Damper bar currents are studied under healthy and broken bar cases. The experimental results are presented and compared to the simulation results to verify the modeling. A special inside-out, round rotor synchronous machine is used for test and verification of the model. The field winding and the damper bars of this machine are mounted on the stator which makes it possible to monitor the bars and end ring currents directly and accurately without using flux probe.

I.

INTRODUCTION

To produce torque in synchronous machines, the rotor must be turning at the same speed as the stator field (i.e., synchronous speed). At any other speed, the rotating field of stator poles will be moving past the rotor poles, first attracting and then repelling them. This condition results in zero average torque and the machine will not start. Using a dc motor or a damper winding, the machine can be brought up to the synchronous speed. Damper windings consist of heavy copper bars, with the two ends shorted together, installed in slots of the rotor pole faces. The interaction of the currents induced in the bars by the rotating air-gap field produces torque. In other words, the machine is started as an induction motor [1]. The dc field current is turned on when the machine is brought near the synchronous speed. When the load is suddenly changed, the damper winding helps damping out the oscillatory motion superimposed on the normal synchronous rotation of the shaft. Diagnostics of broken damper bars in synchronous machines has not been covered as widely as the other faults like eccentricity and inter-turn faults [2-5]. In most operational conditions, when the machine speed is not changed very often, this fault is less frequently reported. During transient, the electromagnetic behavior of asynchronous machines with damper windings is similar to that of an induction machine.

During transient time, when the machine accelerates from zero speed to synchronous speed, a significant current flows in the damper winding. Excessive start-stop cycles or frequent speed changes can cause the breakage of the damper bars. An on-line detection of broken bars has been suggested in [6] by using flux probe and finite element modeling. For the squirrel cage induction machines several methods of detection of broken rotor bars have been reported in the literature.[7-10]. It has been found that in squirrel cage induction machines when a bar breaks most of the current that would have flown in that bar now flows in the two bars immediately adjacent to it on either side. This could result in breakage of several bars [11]. Similar effects have been reported for the converter fed synchronous machines with broken damper bars [12]. This paper describes a WFA based model of a synchronous machine with damper windings. The damper bar currents are the main focus of this paper. It will be presented in this paper that the effect of broken damper bars on the other bar currents is not necessarily similar to that in the induction machines. The bar current distribution depends on the pole saliency and the symmetry between d and q axes. The other factors like the resistance and leakage inductance of the bars and end rings and also the location of the broken bar on the pole can affect the response of the other bar currents to the fault. II. MODELING OF SYNCHRONOUS MACHINES WITH DAMPER WINDING

The development of the d-q model of synchronous machines is based on the assumption that the stator windings are sinusoidally distributed [13]. In other words, all spatial harmonics of the stator windings distributions are neglected. With the actual windings distributions, the usual transformations no longer yield a simplification in the model and the machine analysis becomes complicated. In this study, the coupled magnetic circuit approach is used to derive a synchronous machine model with an m-phase stator windings, one field winding and n rotor damper bars. The machine is simulated in the natural frame of reference. That is, the

978-1-4244-4252-2/09/$25.00 2009 IEEE

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machine is simulated in terms of the actual physical rather than transformed or equivalent variables. A. Armature Voltage Equations Assuming a synchronous machine with m stator windings, one field winding and n damper bars, there will be m+n+2 circuits (including one of the end rings) which are magnetically coupled to each other. These equations are written in three sets of matrix equations. The voltage equations for the stator circuits can then be written as, / (1) = +

11 21 = 1

12 22 2

2 +1 +1

1 +1

(10)

B. Field and Damper Windings equations The field and damper windings are located on the rotor of the synchronous machine. The field winding is coupled with m stator windings and n+1 damper loops. / = + (11)

where the stator flux linkages are given by,

/ = + +

(2)

where, / = + +

(12)

Vs and Is which are the armature voltages and currents can be written as [ = 1 [ = 1 2 2 ] , ] (3) (4)

Rf is the field winding resistance, Lf is the self inductance of the field winding, Lfs = Ltsf is the matrix of the mutual inductances between the field and the stator windings, and Lfd is the matrix of the mutual inductances between the field and damper windings. [ = 1 2 +1 ] (13)

If, the field current and Id, the matrix of the damper bars and end ring currents can be presented by, = [ = 1 2 ,
+1 ]

(5) (6)

Rs is a diagonal m by m matrix given by = (7)

The damper winding which consists of n bars and two end rings can be treated as n+1 loops with independent voltage equations [14]. The damper voltage equations can be written as, / = + (14)

where,
/ = + +

where, the matrix I is an m by m identity matrix and r s is the resistance of each coil assuming all coils are similar. Inductance matrix Ls is a symmetric m by m matrix of the form 11 + 12 1 21 22 + 2 = (8) 1 2 + where, is the leakage inductance of an armature winding and the other terms are the magnetizing and mutual inductances of armature windings. Lsf is an m by 1 matrix comprised of the mutual inductances between the armature coils and the field winding. [ = 1 2 ] (9)

(15)

Lsd is an m by n+1 matrix of the mutual inductances between the armature coils and the damper windings.

Rd is an n+1 by n+1 matrix of the damper winding resistances and Ld is an n+1 by n+1 matrix of the self and the mutual inductances between damper loops including the end ring. Lds = Ltsd is the matrix of the mutual inductances between the damper and the stator windings, and Ldf = Ltfd, is the matrix of the mutual inductances between the field and damper windings. In general the damper loops created by two adjacent bars are not all identical. Usually the bars on the pole faces are spaced uniformly, but there are no bars between the pole faces. In most cases the end ring is continuous, which makes an additional loop. Therefore, there will be n+1 independent voltage equations associated with the damper windings. By manipulating these equations, damper resistance matrix Rd and the damper inductance matrix Ld can be found. Assuming 2k-1 bars per pole and bar #1 located in the middle of the first pole, the kth loop equation corresponds to the intra-pole loop with a larger resistance req and leakage inductance Leq. Fig. 1 shows the circuit model for the damper winding used in deriving the two matrices Rd and Ld. P is the number of poles, rbi is the resistance of the ith bar, re is the end ring resistance of each segment between the bars on

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the pole face, and req is the end ring resistance of intra-pole segments. Different bar resistances are used in the equations to be able to assign a large value to the broken bars when simulating the faulty cases. The damper inductance matrix Ld, which contains the self and mutual inductances of the damper windings, can be derived by collecting the coefficients of the derivatives of the n+1 damper currents in the voltage equations.

is the leakage inductance of the small segments and is the leakage inductance of the intra-pole segments on the end ring. Li,i is the magnetizing inductance of loop i, is the

leakage inductance of each bar, and Li,j is the mutual inductance between loop i and j.

le

re

re r b1

le r bn idn le

l r

eq 1

r eq

r b2 r bk

r eq Idn

k+ b,

lb

i d2

lb
le

id1 re ie

lb re

lb

r b,n
-1

-k+1

l eq

lb
r eq

i dk
l eq
r eq

Idn

-k

r b, lb

lb

n-k

l eq

Figure 1. Damper winding circuit model used to derive Rd and Ld matrices. 1 + 2 + 2 2 1 2 + 3 + 2 0 0 = 0 1 1,1 + 2 + 2 2,1 ,1 ,1 1,2 0 0 0 0 0 0 , 0 0

,1 + ,+1 + 2 ,+1 0 1,1 0 1, 2, 1,+1 2,+1

,1 1 + + 2 ,1 , 1,

( )+ . (16)

2,2 + 2 + 2 2,1 ,2 ,2

,1 , + 2 + 2 ,+1 ,1

2, , + 2 + 2 ( )+ . (17)

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The n damper loop currents are coupled to each other, to the stator and the field windings, through the mutual inductances. But there is no mutual inductance between the end ring and any other windings. III. DERIVATION OF TORQUE EQUATION The mechanical equation of motion depends on the characteristics of the load and is given by,
2 2

where, [ = = [ =0 0 0 0 ] , = [ ] and ] are all (m+n+2) by 1 matrices. 0 0 and = are (m+n+2)

by (m+n+2) matrices. + = (18) All inductances in matrix L, and the derivatives in (22) will EH FDOFXODWHG DQG VDYHG DV D IXQFWLRQ RI URWRU SRVLWLRQ rm over a complete revolution. This matrix is evaluated every iteration EDVHG RQ WKH URWRU SRVLWLRQ rm when solving the differential equations. V. CALCULATION OF INDUCTANCES IN SIMULATION All of the inductances for the concentrated winding synchronous machine can be calculated using WFA given in [13]. For a more realistic model, instead of assuming all turns in a slot are concentrated in one point, one can assume that the n turns are distributed uniformly in the slot. Therefore, the number of turns in the slot is increasing linearly from zero to n over a slot pitch and remains unchanged over a tooth pitch. This makes the winding function trapezoidal. For a better approximation, each positive or negative ramp in the winding function is smoothed out using a sinusoidal approximation. A UDPS IXQFWLRQ ZLWK D FKDQJH RI YDOXH IURP 1 WR 2 EHWZHHQ 1 DQG 2, can be approximDWHG E\ D VLQXVRLGDO IXQFWLRQ I. 1 1 (27) () = 1 2 1 cos
2 2 1

where, J is the rotor moment of inertia, rm is the angular displacement of the rotor, TL is the load torque, and Te is the electromagnetic torque produced by the machine. The electromagnetic torque is related to the magnetic coenergy Wco by, =
( , , )

(19)

In a linear magnetic system the co-energy is equal to the stored magnetic energy so that,
1 2

(20)

Which can be simplified as, 1 ( + + + + =

2 + + + + ( ) 21)

In general, if the slot effect is to be considered, the inductance matrices in this equation are not constant. Taking the derivative of Wco with respect to the rotor mechanical angle, assuming all currents are constant, the electromagnetic torque Te can be derived. =
1 2 + +

+ (22)

The skew effect on the rotor winding function can be modeled in a simple way. If the rotor is not skewed, the number of turns in the winding function will be increased linearly over the slot pitch from zero to n. However, in the case of a skewed rotor, the effective number of turns will increase linearly over the slot pitch plus the skew angle, from zero to n. The skew effect on the winding function is demonstrated in Fig. 2.
60 with skew without skew 40
Armature winding functions

IV. CALCULATION OF CURRENTS IN SIMULATION Given the stator and field voltages, one can solve the differential equations for all the currents. Note that the damper voltages are zero since the bars are all shorted together. The flux linkage equations are given by, = (23)

20

-20

Where, = 1

(24)

The rotor angular frequency and displacement can be obtained by, 1 = ( ) (25)

-40

-60 0

50

100

150 200 Degrees

250

300

350

(26)

Figure 2. Skew effect on the winding function.

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After constructing the winding functions for stator, field and damper windings, and defining the air gap function including slot and skew effects, one can calculate all self and mutual inductances as a function of the rotor position using WFA. VI. EXPERIMENTAL INSIDE-OUT SYNCHRONOUS MACHINE To be able to directly measure and monitor the damper bars currents in a synchronous machine with different types of defects, a special inside-out synchronous machine (IOSM) was built. This machine had the armature winding wound on the rotor, connected to the supply via slip rings, and the field winding mounted in some of the stator slots. A copper cage was built to be placed in the remaining slots aligned with the pole faces. The end ring of the cage was fixed on one side and was removable on the other side. This made it possible to disconnect any of the bars from the end ring for the broken bar test. There were 5 bars per pole and the end ring was continuous. Fig. 3 shows different parts of the special IOSM used for the experiment.

The parameters of the designed IOSM were used for simulation in Matlab. The machine was a three phase 4-pole, round rotor synchronous machine with 36 stator slots and 24 skewed rotor slots. The damper winding had 20 bars, 5 bars per pole and continuous end rings. Fig. 4 shows the damper bars arrangement. Including skewed rotor in the model has a smoothing effect and improves the waveforms. Fig. 5 shows the skew effect on the field, damper bar and armature currents. With the skewed rotor model, the waveforms match closely to the experimental results.
with skew without skew 10

Damper bar#1 current

-5

-10 0.5 0.505 Time 0.51 0.515

(a)
with skew without skew 0.6

(a)

(b)
field current

0.55

0.5

0.45

0.4

0.35 0.5

0.505

0.51

0.515

0.52 Time

0.525

0.53

0.535

0.54

(c ) (d) Figure 3. Different parts of IOSM: (a) Field windings on the stator, (b) Damper cage with the removable end ring on the stator, (c) Armature windings on the rotor, (d) IOSM.
armature current

(b)
0.8
with skew without skew

0.6 0.4

0.2 0 -0.2 -0.4 -0.6 -0.8 0.5

9 10 11 12 13

3 2 1 20 19

0.505

0.51

0.515

0.52 Time

0.525

0.53

0.535

0.54

14 15

16

17

18

(c) Figure 5. Skew effect in simulation, (a) Damper bar current, (b) Field current, (c) Armature current.

Figure 4. Damper bars arrangement

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In Fig. 6, the currents in the armature winding and damper bar #1 are demonstrated in a healthy machine. In Fig. 7, the current in bar#1 is shown in two different faulty cases, one broken bar (bar #3) and two broken bars (bar #2 and #3). With one broken bar the change of current in the bar not immediate adjacent to the broken bar is not significant. However, the current in the immediate adjacent to the broken bar is reduced. In the case of two broken bars, this change is more significant. It can be observed that the simulation waveforms match closely to the experimental results. (a)
4 3 2
bar #1 current

(b)

1 0 -1 -2 -3

(a)
4 3 2
Armature current

(b)

-4 0.302

0.304

0.306 Time

0.308

0.31

0.312

(c)
4 3 2 1 0 -1 -2 -3 -4 0.302

1 0 -1 -2 -3 -4 0.3
bar#1 current

0.31

0.32

0.33 Time

0.34

0.35

0.36

(c)
4 3 2

0.304

0.306 Time

0.308

0.31

0.312

bar current #1

1 0 -1 -2 -3 -4 0.3

(d) Figure 7. Bar #1 current (a) Experimental results when bar #3 is broken (1ms,1A/div), (b) Experimental results when bar #2 and #3 are broken (1ms,1A/div), (c) and (d) simulation results of case a and b. Fig. 8 shows the change in the bar current when one adjacent bar is broken. It can be observed that the current is slightly lower in the healthy case. Similar results are obtained for the two broken bars case as shown in Fig. 9. The current in the bar adjacent to the two broken bars is reduced more significantly. When a damper bar breaks, a big loop will be created with higher inductances, leading to higher flux linkage. At the same time, the resistance of the loop will be increased as well. Since the damper bars are shorted out through the end rings, the damper voltage is zero. With x representing the new damper

0.302

0.304

0.306 Time

0.308

0.31

0.312

(d) Figure 6. Healthy armature current and bar #1 current. (a) and (b) Experimental (1ms,1A/div), (c) and (d) Simulation

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loop created after the fault, the voltage equation corresponding to new loop will be +

0.03 healthy one bb two bb

0.02

=0

(28)
0.01
bar #1 current /100

Therefore, the response of the current in the adjacent bar to the broken bars is determined by the rate at which Rx and Gx/dt will increase after the fault. If the rate of increase in Rx is higher compared to that in G[GW, then the current in the bar adjacent to the broken bar will be reduced. Similar phenomenon occurs in the squirrel cage induction machines in the case of broken rotor bars. In this case however, the rotor resistance will change after the fault and a new torque-speed curve will govern the behavior of the machine. After the fault, at the same torque, as the speed jumps from the original torque-speed curve to the new one, an increase in the rotor current will be dictated by the current speed curve. That is why the currents in the bars adjacent to the broken bar will always increase in induction machines.
0.04 0.03 0.02
bar #2 current /100

-0.01

-0.02

-0.03

-0.04 -2

4 time

8 x 10

10
-3

(a)
3
healthy one broken bar two broken bars

2 healthy one bb
Bar #1 Current

0.01 0

-1

-2 -0.01 -3 -0.02 -0.03 -0.04 -2 -4 0.4 0.402 0.404 0.406 Time 0.408 0.41

4 time

8 x 10

10
-3

(b) Figure 9. Current in bar #1 when two adjacent bars ( #2 and #3) are broken, (a) Experiments (1ms,1A/div), (b) Simulations.

(a)
4 3 2
Bar #2 Current /100

one broken bar healthy

VII. CONCLUSIONS The equations describing the performance of a synchronous machine with damper windings, including the computation of all machine inductances were derived using winding function approach. In deriving these equations the space harmonics and skew effect were specifically included. The parameters of the model were calculated directly from the geometry and winding layout of the machine without any transformation or neglecting the harmonics. Equations for calculation of all currents and electromagnetic torque were derived to account for non sinusoidal air gap flux distributions. Finally a special IOSM designed for experiment, was simulated using this model. With this machine the bar currents were measured directly and accurately with a current probe. The bar current waveforms in the healthy and faulty cases were investigated and compared in the simulations and experiments.

1 0 -1 -2 -3 -4 0.4

0.402

0.404

0.406 Time

0.408

0.41

(b) Figure 8. Current in bar #2 when the adjacent bar #3 is broken, (a) Experiment (1ms,1A/div), (b) Simulation

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It was found that unlike induction machines, in synchronous machines one or more broken damper bars could reduce the adjacent bar currents. the response of the current in the adjacent bar to the broken bars is determined by the rate at ZKLFK 5[ DQG G[GW ZLOO LQFUHDVH DIWHU WKH IDXOW ,I WKH UDWH RI LQFUHDVH LQ 5[ LV KLJKHU FRPSDUHG WR WKDW LQ G[GW WKHQ WKH current in the bar adjacent to the broken bar will be reduced. The test results verified the accuracy of the model for both the healthy and faulty cases. This model can be used to find the signatures of different type of faults to be used for diagnostics and condition monitoring of the synchronous machines. REFERENCES
[1] G. McPherson and R.D. Laramore, Electrical Machines and Transformers, John Wiley, 1990. >@ 3 1HWL DQG 6 1DQGL $QDO\VLV DQG 0RGHOLQJ RI D 6\QFKURQRXV 0DFKLQH ZLWK 6WUXFWXUDO $V\PPHWULHV ,(((-Canadian Conference on Electrical and Computer Engineering, Ottawa, Canada, May 2006. [3] 3 1HWL DQG 6 1DQGL 6WDWRU ,QWHU-turn Fault Detection of 6\QFKURQRXV 0DFKLQHV 8VLQJ )LHOG &XUUHQW 6LJQDWXUH $QDO\VLV IEEE-Industry Applications Conference, Tampa, USA, Oct. 2006. [4] N.A. Al-1XDLP DQG + $ 7ROL\DW $ 0HWKRG IRU '\QDPLF Simulation and Detection of Dynamic Air Gap Eccentricity in SynchrRQRXV 0DFKLQHV IEEE international Electric Machines and Drives Conference, May 1997 [5] H.A. Toliyat and N. A. Al-1XDLP Simulation and detection of dynamic air-gap eccentricity in salient-pole synchronous machines ,((( 7UDQV ,QGXVWU\ $SSOLFDWLRQs , Vol. 35, Issue. 1, Jan-Feb 1999. [6] +& .UDPHU %URNHQ 'DPSHU %DU 'HWHFWLRQ 6WXGLHV 8VLQJ Flux Probe Measurements and Time-stepping Finite Element $QDO\VLV IRU 6DOLHQW 3ROH 6\QFKURQRXV 0DFKLQHV IEEE International Symposium on Diagnostics for Electric Machines, Power Electronics and Drives, SDEMPED 2003, Issue , 24-26 Aug. 2003 Page 193 197 [7] M. Negrea, S. Poyhonen, A. Arkkio, P. Jover and H. Hyotyniemi, 0odeling, Simulation and Signal Processing with Application to Electric Machine Fault Diagnostics and Condition 0RQLWRULQJ 3URFHHGLQJV RI the International Conference on Modeling and Simulation of Electric Machines, Converters and Systems, Montreal, Canada,. August 2002. [8] R. Povinelli, J. Bangura, N. Demerdash and R. Brown, 'LDJQRVWLFV RI Bar and End-Ring Connector Breakage Faults in Polyphase Induction Motors Through a Novel Dual Track of Time-Series Data Mining and Time-Stepping Coupled FE-State 6SDFH 0RGHOLQJ ,((( Transactions on Energy Conversion, Vol. 17, No. I , p. 39, March 2002. [9] ,QGXFWLRQ 0DFKLQHV 8VLQJ 0HDVXUHPHQW RI 6KDIW &XUUHQWV Proceedings of the International Symposium on Diagnostics for Electric Machines, Power Electronics and Drives (SDEMPED). 2001. [10] 1 (ONDVDEJ\ $ (DVWKDP DQG * 'DZVRQ 'HWHFWLRQ RI %URNHQ BaUV LQ WKH &DJH 5RWRU RQ DQ ,QGXFWLRQ 0DFKLQH ,((( Transactions on Industry Applications, Vol. 28, No. I , p. 165, January 1992. [11] G.B. Kliman, R. A Koegl 1RQLQYDVLYH GHWHFWLRQ RI EURNHQ rotor bars iQ RSHUDWLQJ LQGXFWLRQ PRWRUV IEEE Trans. Energy Conversion, Vol. 3, Dec. 1988.

[12] S.B. Jovanovski, &DOFXODWLRQ DQG 7HVWLQJ RI 'DPSHU-Winding Current Distribution in a Synchronous Machine with Salient 3ROHV ,((( 7UDQV RQ 3RZHU $SSDUDWXV DQG 6\VWHPV  9RO PAS-88, Issue 11. Nov. 1969. [13] T.A. Lipo, Theory and Control of Synchronous Machines, University of Wisconsin-Madison, 1987. [14] +$ 7ROL\DW DQG 7$ /LSR 7UDQVLHQW $QDO\VLV RI &DJH Induction Machines Under Stator, Rotor Bar and End Ring )DXOWV ,((( 7UDQV (QHUJ\ &RQYHUVLRQ 9RO  No. 2, June 1995.

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