Search for Author, Title, Keyword
Failure analysis of a high-speed induction machine driven by a SiC-inverter and operating on a common shaft with a high-speed generator
More details
Hide details
Polish Academy of Sciences, Institute of Fluid Flow Machinery, ul. Fiszera 14, 80-231 Gdańsk, Poland
Gdańsk University of Technology, Faculty of Electrical and Control Engineering, Gabriela Narutowicza 11/12, 80-233, Gdańsk, Poland
SGI Engineering, MMB Drives Sp. z o.o., Maszynowa 26, 80-298 Gdańsk, Poland
Publication date: 2022-03-31
Eksploatacja i Niezawodność – Maintenance and Reliability 2022;24(1):177-185
  • A numerical analysis of the failure of a high-speed turbomachine was performed.
  • Run-out analysis was carried out after the failure was performed.
  • Modifications to the design of a test rig for highspeed generators were analysed.
  • Rolling bearings and their influence on rotor dynamics were analysed.
Due to ongoing research work, a prototype test rig for testing high speed motors/generators has been developed. Its design is quite unique as the two high speed machines share a single shaft with no support bearings between them. A very high maximum operating speed, up to 80,000 rpm, was required. Because of the need to minimise vibration during operation at very high rotational speeds, rolling bearings were used. To eliminate the influence of higher harmonics of supply voltage and current on the formation of torque oscillations on the shaft and excessive losses in the form of heat, a voltage source inverter with high switching silicon carbide (SiC) power transistors characterizing high precision of the output voltage generation with a fundamental harmonic frequency of several kilohertz has been used. During the first start-ups, it turned out that the system was not stable, and a failure occurred. The paper presents the consequences that may arise when a machine operating at a speed of about 70,000 rpm fails. The article contains pictures of a generator failure that occurred at a high rotational speed.
Abdou KM, Saber E. Effect of rotor misalignment on stability of journal bearings with finite width. Alexandria Engineering Journal 2020; 59(5): 3407–3417,
Antipov VN, Danilevich YB. High-speed electrical machines for power engineering: Current state and development trends. Russian Electrical Engineering 2007; 78(6): 277–279,
Antivachis M, Dietz F, Zwyssig C et al. Novel high-speed turbo compressor with integrated inverter for fuel cell air supply. Frontiers in Mechanical Engineering 2021; 6(February): 1–13,
Arkkio A, Jokinen T, Lantto E. Induction and permanent-magnet synchronous machines for high-speed applications. 2005 International Conference on Electrical Machines and Systems, IEEE: 2005: 871–876,
Breńkacz Ł, Żywica G, Bogulicz M. Selection of the Bearing System for a 1 kW ORC Microturbine. Mechanisms and Machine Science, 2019; 60: 223–235,
Breńkacz Ł, Żywica G, Bogulicz M. Numerical Analysis of the Rotor of a 30 kW ORC Microturbine Considering Properties of Aerodynamic Gas Bearings. Mechanics and Mechanical Engineering 2018; 22(2): 425–436,
Breńkacz Ł, Żywica G, Bogulicz M. Analysis of dynamical properties of a 700 kW turbine rotor designed to operate in an ORC installation. Diagnostyka 2016; 17(2): 17–23.
Carpenter AL, Beechner TL, Tews BE, Yelvington PE. Hybrid-electric turbocharger and high-speed SiC variable-frequency drive using sensorless control algorithm. Journal of Engineering for Gas Turbines and Power 2018; 140(12): 1–8,
Castilla-Gutiérrez J, Fortes Garrido JC, Davila Martín JM, Grande Gil JA. Evaluation procedure for blowing machine monitoring and predicting bearing skfnu6322 failure by power spectral density. Eksploatacja i Niezawodnosc - Maintenance and Reliability 2021; 23(3): 522–529,
Du G, Huang N, Zhao Y et al. Comprehensive Sensitivity Analysis and Multiphysics Optimization of the Rotor for a High Speed Permanent Magnet Machine. IEEE Transactions on Energy Conversion 2021; 36(1): 358–367,
Gerlach ME, Zajonc M, Ponick B. Mechanical stress and deformation in the rotors of a high-speed PMSM and IM. Elektrotechnik und Informationstechnik 2021; 138(2): 96–109,
Giziewski S. Trójfazowy falownik napięcia z tranzystorami SiC JFET. Przegląd Elektrotechniczny 2012; 88(4b): 76–79.
He J, Li C, Jassal A et al. Multi-domain design optimization of dv/dt filter for SiC-based three-phase inverters in high-frequency motor-drive applications. IEEE Transactions on Industry Applications 2019; 55(5): 5214–5222,
Ismagilov FR, Uzhegov N, Vavilov VE et al. Multidisciplinary Design of Ultra-High-Speed Electrical Machines. IEEE Transactions on Energy Conversion 2018; 33(3): 1203–1212,
15. ISO 1940-1:2003 Mechanical vibration - balance quality requirements for rotors in a constant (rigid) state. Part 1: Specification and verification of balance tolerances. 2003: 1–28.
Kim D, O’Connor J, Schwenne F, Drumm M. Design and test of an advanced system for energy generation. 2020.
Krähenbühl D, Zwyssig C, Bitterli K et al. Evaluation of ultra-compact rectifiers for low power, high-speed, permanent-magnet generators. IECON Proceedings Industrial Electronics Conference 2009; (Cm): 448–455,
Kuznetsov AP, Stankevich NV, Shchegoleva NA. Synchronization of coupled generators of quasi-periodic oscillations upon destruction of invariant curve. Izvestiya Vysshikh Uchebnykh Zavedeniy. Prikladnaya Nelineynaya Dinamika 2021; 29(1): 136–159, https://doi. org/10.18500/0869-6632-2021-29-1-136-159.
Lee J I, Bang TK, Lee HK et al. Design of the high‐speed pmsg with two different shaft material considering overhang effect and mechanical characteristics. Applied Sciences (Switzerland) 2021; 11(16): 0–8,
Lee TW, Hong DK. Electrical and mechanical characteristics of a high-speed motor for electric turbochargers in relation to eccentricity. Energies 2021. doi:10.3390/en14113340,
Liu L, Guo Y, Lei G, Zhu J. Design and Analysis Technologies of High Speed Permanent Magnet Machines. 2021 31st Australasian Universities Power Engineering Conference (AUPEC), 2021: 1–6,
Liu T, Wong TTY, Shen ZJ. A survey on switching oscillations in power converters. IEEE Journal of Emerging and Selected Topics in Power Electronics 2020; 8(1): 893–908,
Loncarski J, Monopoli VG, Leuzzi R et al. Analytical and simulation fair comparison of three level Si IGBT based NPC topologies and two level SiC MOSFET based topology for high speed drives. Energies 2019; 12(23): 1–16,
Lu Y, Zhang X, Zhu C et al. On-line Estimation of Current Harmonics for Status Monitoring and Diagnosis of High-Speed Permanent Magnet Synchronous Motors. 2021 IEEE International Conference on Mechatronics (ICM), 2021: 1–6,
Pottie DLF, Mendonça GA, Faria OA et al. Some aspects of the electromechanical design of high-speed microturbines for power generation. International Journal of Applied Electromagnetics and Mechanics 2020; 63(4): 621–644,
Pranta MH, Rabbi MS, Banik SC et al. A computational study on structural and thermal behavior of modified disk brake rotors. Alexandria Engineering Journal 2021,
Qiu H, Zhao X, Wei Y et al. Comparative analysis of super high-speed permanent magnet generator electromagnetic and temperature fields with the PWM and uncontrolled rectifiers. EPE Journal 2020; 30(4): 181–191,
Rubanenko O, Gundebommu S L, Hunko I, Peroutka Z. Analysis of development directions of online diagnostics of synchronous generator. Przegląd Elektrotechniczny 2021; 1(4): 22–28,
Schaeffler. Super precision bearings. 2019: 262.
Schmied J, Perucchi M, Pradetto J C. Application of madyn 2000 to rotordynamic problems of industrial machinery. Proceedings of the ASME Turbo Expo 2007; 5(November): 799–810,
Skowronek K. FFT-PCA-LDA classifier in A.C . generator diagnostics. Eksploatacja i Niezawodnosc – Maintenance and Reliability 2013; 15(2): 140–146.
Sliż P, Wycinka E. Identification of factors that differentiate motor vehicles that have experienced wear or failure of brake system components during the warranty service period. Eksploatacja i Niezawodnosc 2021; 23(3): 430–442,
Stumpf P, Bara I. Model predictive torque control with synchronized sampling frequency for high frequency induction machine drives. IEEE International Symposium on Industrial Electronics 2020; 2020-June: 332–338,
Stumpf P, Varga Z, Bartal P et al. Effect of subharmonics on the operation of ultrahigh speed induction machines. IECON Proceedings Industrial Electronics Conference 2009: 426–431,
Zhang C, Chen L, Wang X, Tang R. Loss calculation and thermal analysis for high-speed permanent magnet synchronous machines. IEEE Access 2020; 8: 92627–92636,
Zwyssig C, Kolar J W, Thaler W, Vohrer M. Design of a 100 W, 500000 rpm permanent-magnet generator for mesoscale gas turbines. Conference Record - IAS Annual Meeting IEEE Industry Applications Society 2005; 1(Im): 253–260,
Żywica G, Kaczmarczyk T Z, Breńkacz Ł et al. Investigation of dynamic properties of the microturbine with a maximum rotational speed of 120 krpm – predictions and experimental tests. Journal of Vibroengineering 2020; 22(2): 298–312,
Asynchronous motor mW 5.4/6-2-52c/52cr9 data sheet. e+a Elektromaschinen und Antriebe AG, 2010.
Synchronous motor mSpW 5.5/ 4.5-4-a1 ENCA data sheet. e+a Elektromaschinen und Antriebe AG, 2010.
Comparative Evaluation of the Tribological Properties of Polymer Materials with Similar Shore Hardness Working in Metal–Polymer Friction Systems
Daniel Pieniak, Radosław Jedut, Leszek Gil, Włodzimierz Kupicz, Anna Borucka, Jarosław Selech, Grzegorz Bartnik, Krzysztof Przystupa, Zbigniew Krzysiak
Effect of clearance on the dynamic characteristics of high-speed rolling bearings with multiple defects
Yunlong Li, Zhinong Li, Deqiang He, Fei Wang
Mechanical Systems and Signal Processing
Review of Methods for Diagnosing the Degradation Process in Power Units Cooperating with Renewable Energy Sources Using Artificial Intelligence
Paweł Ziółkowski, Marta Drosińska-Komor, Jerzy Głuch, Łukasz Breńkacz
Journals System - logo
Scroll to top