As an important part of motor or generator, the fault diagnosis of rotary transformer is very important to ensure the normal operation of equipment. The following is a detailed discussion of rotating transformer fault diagnosis methods to provide a comprehensive and in-depth understanding.
I. Introduction
Rotating transformer（resolver）, based on the law of electromagnetic induction, through the change of rotation Angle to sense the electromotive force, to achieve power transmission or position detection and other functions. Because it is widely used in industrial automation, servo control, aerospace and other fields, the accuracy and timeliness of its fault diagnosis has an important impact on the stable operation of the system.
2. Overview of fault diagnosis methods
The fault diagnosis methods of rotary transformer are various, including visual inspection, electrical parameter measurement, vibration analysis, thermal infrared detection, sound analysis and comprehensive test analysis. These methods have their own emphasis and can be used comprehensively and accurately to diagnose the fault of rotating transformer.
3. Specific fault diagnosis methods
1. Visual examination
Objective: To determine whether the rotary transformer has external damage or abnormal.
Steps:
Check the appearance: Observe whether the shell of the rotating transformer has cracks, oil leakage, burning and other phenomena.
Check the insulation material: Check whether the external insulation material is cracked, cracked, or peeled.
Check the cable: confirm whether the cable is tight, loose or corroded.
Check rotating parts: Pay attention to check the wear of rotating parts such as bearings, gears and racks.
Note: Visual inspection is the first step in troubleshooting and can quickly detect obvious signs of external failure.
2. Measurement of electrical parameters
Objective: To determine whether the rotating transformer has electrical faults by measuring the electrical parameters.
Steps:
Use equipment: Use digital multimeter or special electrical testing equipment.
Measurement parameters: including current, voltage, temperature, power factor, etc.
Comparative analysis: The measurement results are compared with normal parameters to analyze whether the difference is beyond the normal range.
Note: Electrical parameter measurement is an important means to judge electrical faults, and it is necessary to accurately record and analyze the measurement results.
3. Vibration analysis
Objective: To measure and analyze the vibration data to determine whether there is mechanical fault in the rotating transformer.
Steps:
Equipment used: vibration measuring equipment such as acceleration sensor.
Data collection: Vibration data is collected while the rotating transformer is in operation.
Data analysis: Using vibration analysis software to process data and identify vibration characteristics, such as frequency, amplitude, etc.
Fault judgment: According to the vibration characteristics to determine whether there is bearing wear, imbalance, loosening and other faults.
Note: Vibration analysis can quickly detect mechanical faults, but requires professional analysis of vibration data.
4. Thermal infrared detection
Objective: To determine whether there is overheating problem by detecting the heat distribution inside the rotary transformer.
Steps:
Equipment used: infrared thermal imager.
Heat map observation: Observe the heat map of the rotating transformer and pay attention to the abnormal temperature area.
Fault diagnosis: Analyze the heat map to determine whether there are overheating problems such as poor coil contact and aging insulation materials.
Note: Thermal infrared detection can detect internal faults without contact, but it is necessary to pay attention to the temperature difference between the environment and the device itself.
5. Sound analysis
Objective: To detect the sound produced by the rotating transformer to determine whether there is noise, vibration and other problems.
Steps:
Equipment used: dedicated sound sensor.
Sound collection: Collect sound data while the rotary transformer is in operation.
Sound analysis: Processing sound data to identify sound characteristics, such as frequency, loudness, etc.
Fault diagnosis: According to the sound characteristics, determine whether there is a fault in the bearing, gear, rack and other components.
Note: Sound analysis can directly reflect the operating status of the rotating transformer, but it needs to pay attention to the interference of environmental noise.
6. Comprehensive test analysis
Objective: To comprehensively evaluate the performance of rotary transformers through a series of tests and analyses.
Steps:
Equipment used: high voltage tester, insulation resistance tester, etc.
Test items: including voltage test, insulation resistance test, load test, etc.
Result analysis: According to the test results, the performance of the rotary transformer is analyzed to determine whether there is a fault.
Note: Comprehensive test analysis is the ultimate means of fault diagnosis and can fully assess the health status of the rotating transformer.
4. Fault diagnosis process
In practical application, the fault diagnosis of rotary transformer should follow a certain process to ensure the accuracy and high efficiency of diagnosis. The following is a typical troubleshooting process:
Appearance inspection: First of all, visual inspection is carried out to preliminarily determine whether there is external damage or abnormality of the rotating transformer.
Electrical parameter measurement: Use electrical testing equipment to measure the electrical parameters of the rotating transformer, and compare and analyze the normal parameters.
Vibration analysis: The use of vibration measurement equipment to collect vibration data, and professional analysis to determine whether there is a mechanical fault.
Thermal infrared detection: Use an infrared thermal imager for thermal infrared detection to observe the heat distribution inside the rotating transformer, identify whether there is overheating or thermal uneven areas, and further analyze potential fault sources.
Sound analysis: When the rotary transformer is running, the sound sensor is used to collect its operating sound, and the sound characteristics are analyzed to determine whether there is abnormal noise, such as bearing wear, imbalance or mechanical loosening.
Comprehensive evaluation and diagnosis: The results of the above testing and analysis are summarized, combined with the operating history, working environment, service status and other factors of the rotary transformer, and a comprehensive evaluation is carried out. Use professional knowledge to determine the specific location and nature of the fault, such as electrical fault, mechanical fault, insulation fault, etc.
Fault location and confirmation: On the basis of comprehensive assessment, further detailed inspection of the suspected fault area is carried out, and disassembly analysis is carried out if necessary to accurately locate the fault point and confirm the fault type.
Fault report and record: Prepare a detailed fault report, record the fault phenomenon, detection process, analysis results, fault location and confirmation, and suggested repair or replacement plan. In addition, the fault report and detection data are saved to provide reference for subsequent fault prevention and maintenance.
Repair and replacement: Repair or replace the rotating transformer according to the fault report and maintenance plan. In the maintenance process, it is necessary to strictly abide by the operating procedures to ensure the maintenance quality; Select a suitable replacement and perform necessary debugging and testing.
Test and verification: After the repair or replacement is completed, the rotating transformer is tested and verified to ensure that its performance returns to normal and meets the requirements of use. The test content includes electrical performance, mechanical performance, thermal performance and other aspects of the test.
Fault prevention and maintenance: According to the problems and hidden dangers found in the process of fault diagnosis, formulate specific fault prevention and maintenance measures. Strengthen the daily inspection and regular maintenance of the rotating transformer, discover and deal with potential faults in time, and improve the reliability and service life of the equipment.
Precautions for fault diagnosis
Safety first: When fault diagnosis and maintenance work, you must strictly abide by the safe operation procedures to ensure personal safety and equipment safety.
Accurate records: Record the operation and detection results of each step in the fault diagnosis process in detail, providing a basis for subsequent fault analysis and maintenance.
Professional analysis: Fault diagnosis requires the support of professional knowledge and skills. Ensure that the personnel involved in fault diagnosis have the corresponding qualifications and experience.
Comprehensive consideration: Fault diagnosis should take into account the operation history, working environment, use status and other factors of the rotating transformer, to avoid one-sided or wrong judgment.
Timely handling: Once a fault is detected, take immediate measures to prevent the fault from spreading or causing more serious consequences.
Continuous improvement: By constantly summarizing the experience and lessons of fault diagnosis, improving the fault prevention and maintenance measures to improve the reliability and stability of the rotary transformer.
Vi. Conclusion
The fault diagnosis of rotating transformer is a complicated and important process, which requires the comprehensive application of many detection methods and analysis means. Through visual inspection, electrical parameter measurement, vibration analysis, thermal infrared detection, sound analysis and comprehensive test analysis, the fault type and location of the rotating transformer can be diagnosed comprehensively and accurately. In the process of fault diagnosis, attention should be paid to safety, accurate record, professional analysis, comprehensive consideration, timely treatment and continuous improvement. Only in this way can the normal operation of the rotating transformer and the long-term stability of the equipment be ensured.
