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Utilization of two sensors in offline diagnosis of squirrel-cage rotors of asynchronous motors

Abstract

In the manufacture squirrel-cage rotors of asynchronous motors, a high standard of quality is required in every part of the production cycle. The die casting process usually creates porosity in the rotor bars. This most common defect in the rotor often remains hidden during the entire assembly of the machine and is usually only detected during final testing of the motor, i.e., at the end of the production process. This leads to unnecessary production costs. Therefore, the aim is to conduct a continuous control immediately after the rotor has been cast before further processing. In our paper, we are interested in selecting a suitable method of offline rotor diagnostics of an asynchronous motor that would be effective for these needs. In the first step, the selection of the method and its integration into the overall manufacturing process is carried out. The arrangement of the sensors and their calibration is then simulated on a 2D Finite Element Model of the rotor. The proposed offline measurement procedures and technologies are finally validated by testing measurements on a rotor that simulates the most frequently occurring faults. A test system is also developed that provides the operator continuous information about the running rotor measurements and makes it easier to evaluate the quality of the cast rotor by means of graphical visualization of the faults.

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Utilization of two sensors in offline diagnosis of squirrel-cage rotors of asynchronous motors

Author: Kačor, Petr
Publisher: MDPI
Year: 2021
DOI: 10.3390/en14206573
Source: https://dspace.vsb.cz/bitstreams/7038fdae-84e0-4395-b700-23864ca6f70b/download
ene gies
A icle
U iliza ion o Two Senso s in O line Diagnosis o
Squi el-Cage Ro o s o Asynch onous Mo o s
Pe Kaco * , Pe Be na and Pe Mold ik


Ci a ion: Kaco , P.; Be na , P.;
Mold ik, P. U iliza ion o Two Senso s
in O line Diagnosis o Squi el-Cage
Ro o s o Asynch onous Mo o s.
Ene gies 2021,14, 6573. h ps://
doi.o g/10.3390/en14206573
Academic Edi o : Maciej Sułowicz
Recei ed: 4 Sep embe 2021
Accep ed: 10 Oc obe 2021
Published: 13 Oc obe 2021
Publishe ’s No e: MDPI s ays neu al
wi h ega d o ju isdic ional claims in
published maps and ins i u ional a il-
ia ions.
Copy igh : © 2021 by he au ho s.
Licensee MDPI, Basel, Swi ze land.
This a icle is an open access a icle
dis ibu ed unde he e ms and
condi ions o he C ea i e Commons
A ibu ion (CC BY) license (h ps://
c ea i ecommons.o g/licenses/by/
4.0/).
Depa men o Elec ical Powe Enginee ing a VSB, Technical Uni e si y o Os a a, 17. Lis opadu 2172/15,
708 00 Os a a-Po uba, Czech Republic; pe [email p o ec ed] (P.B.); pe [email p o ec ed] (P.M.)
*Co espondence: pe [email p o ec ed]
Abs ac :
In he manu ac u e squi el-cage o o s o asynch onous mo o s, a high s anda d o quali y
is equi ed in e e y pa o he p oduc ion cycle. The die cas ing p ocess usually c ea es po osi y in
he o o ba s. This mos common de ec in he o o o en emains hidden du ing he en i e assembly
o he machine and is usually only de ec ed du ing inal es ing o he mo o , i.e., a he end o he
p oduc ion p ocess. This leads o unnecessa y p oduc ion cos s. The e o e, he aim is o conduc
a con inuous con ol immedia ely a e he o o has been cas be o e u he p ocessing. In ou
pape , we a e in e es ed in selec ing a sui able me hod o o line o o diagnos ics o an asynch onous
mo o ha would be e ec i e o hese needs. In he i s s ep, he selec ion o he me hod and i s
in eg a ion in o he o e all manu ac u ing p ocess is ca ied ou . The a angemen o he senso s and
hei calib a ion is hen simula ed on a 2D Fini e Elemen Model o he o o . The p oposed o line
measu emen p ocedu es and echnologies a e inally alida ed by es ing measu emen s on a o o
ha simula es he mos equen ly occu ing aul s. A es sys em is also de eloped ha p o ides
he ope a o con inuous in o ma ion abou he unning o o measu emen s and makes i easie o
e alua e he quali y o he cas o o by means o g aphical isualiza ion o he aul s.
Keywo ds:
squi el-cage; aul de ec ion; b oken ba ; o line diagnosis; FEM simula ion; signal
p ocessing; o al pa e ns
1. In oduc ion
In he p oduc ion o asynch onous machine o o s, we o en encoun e he need o es
hei manu ac u ing quali y du ing p oduc ion. This ype o es ing can de ec a p oduc ion
de ec in he o o ea ly on, immedia ely a e he o o has been cas and emo ed om he
die cas ing mold. O he wise, his de ec would only appea a he end o he manu ac u ing
p ocess o he elec ic mo o du ing i s ou pu es ing [
1
,
2
]. In his case, he mo o is s ill
epai able by o al o o eplacemen . This me hod adds eno mous ex a manu ac u ing
cos s. Mo eo e , a comple e o o eplacemen is e y di icul o pe o m in he mass
p oduc ion o elec ic machines. Addi ional cos s a e incu ed in all he echnological
ope a ions ha he o o goes h ough a e cas ing. These include he p essing o he sha
in o he s a o pack, he adjus men o he o o dimensions and i s su ace, he o e all
balancing o he o a ing masses, he p essing o he bea ings on o he sha , and i s inal
ixing o he ame wi h he s a o [2].
Ro o manu ac u ing ailu es can be di ided in o wo ca ego ies acco ding o he
signi icance o he ailu e: majo and mino [
3
,
4
]. Majo de ec s can be de ec able by he
naked eye o by using image p ocessing [
5
–
7
]. These include b oken ba s, ba s sepa a ed
om he ings, bulging ma e ial on he o o su ace, o comple ely missing ma e ial in
he ing o ba . Mino de ec s in cas o o s a e mainly caused by ai bubbles in he ba s
and end- ings o in e nal ma e ial de o ma ion caused by in ensi e cooling o he mol en
me al [
8
]. A o o wi h such de ec s may seem isual o be pe ec ly ine, bu om an
elec ical iew, i has educed esis ance, which may be une enly dis ibu ed be ween he
Ene gies 2021,14, 6573. h ps://doi.o g/10.3390/en14206573 h ps://www.mdpi.com/jou nal/ene gies
Ene gies 2021,14, 6573 2 o 23
ba s and end- ings [
8
,
9
]. In he case o die-cas o o cages, whe e he ings a e in di ec
con ac wi h he o o packing, isual inspec ion e en by an expe ienced echnician may be
unsuccess ul and mino de ec s p ac ically unde ec able [2,4].
The in e nal shape o he o o ba s and hei o e all a angemen can also be e y
a ied, e.g., single s aigh ba s, skewed ba s, and single o double cage o o s. The shape
o a owed o o ba s wi h a middle ing is also o en ound [
10
,
11
]. The o o slo s can be
open, semi-closed, o ully closed [
12
–
14
]. The a iabili y o he o o s, in gene al, makes
he iden i ica ion o ailu es di icul and is qui e insu icien in mul i-se ies p oduc ion o
cas o o s.
Du ing se e al decades, e y high-quali y me hods ha e been de eloped and elab-
o a ed, which a e oday commonly used o iden i y machine ailu es based on online
diagnos ics [
15
–
20
]. These me hods a e use ul du ing ope a ion when disassembly o he
elec ic mo o is no equi ed. Faul measu emen s can be pe o med a a sa e dis ance
om he machine [
21
]. Widely used echniques a e, e.g., single-phase es wi h educed
machine supply, MSCA (Mo o Signa u e Cu en Analysis), o diagnos ics om he s ay
ield in adial o axial di ec ion [
21
,
22
]. Al hough hese me hods can de ec mino o o
aul s, such a sys em is no sui able o diagnosing a single o o a e cas ing because i
equi es a machine s a o . In an assembled machine, he es esul s can also be a ec ed
by he condi ion o o he mo o componen s such as he s a o , i s magne ic ci cui wi h
windings, bea ings, e c. [23,24].
To de ec ailu es in he squi el-cage o o immedia ely a e die cas ing, i is necessa y
o sea ch in an o -line es g oup ha does no include any mo o componen s o he han he
o o i sel . In his a ea, we can ind, o example, magne ic oil diagnos ics, dye pene an ,
DLRO (Digi al Low Resis ance Ohmme e ) measu emen s, o ul asonic measu emen s o
de e mine he quali y o he end- ings [
25
]. The e also exis s a me hod ha equi es high
cu en exci a ion (HCE) in which local ho spo s on he o o su ace a e measu ed using
an IR came a. The empe a u e can each high alues and he lowing cu en s can dis o
he measu ing equipmen [3,4].
The G owle es is his o ically he oldes o -line me hod o measu ing o o quali y.
I was o iginally used o winding o o s o commu a o machines o loca e in e - u n
connec ions o in e up ed connec ions o he winding ou pu s o he commu a o [
26
].
The G owle yoke exci es an AC magne ic ield in he o o , which induces a ol age in
he ba s (windings). When a pa o he winding is in e up ed o sho -ci cui ed, a local
change in he magne ic ield is p oduced on he o o su ace. The change in he ield can be
de ec ed by e omagne ic iden i ica ion ape, magne ic oil, Hall senso , o by compa ing
he change in supply cu en as o he o o slowly o a es. Fo bes sensi i i y, he o o is
usually in di ec con ac wi h he poles o he G owle yoke [27].
O he me hods use di ec analysis o he magne ic ield esponse o measu emen
o he magne ic induc ion alue nea he o o su ace o es he o o . The o o usually
o a es a a slow speed du ing he measu emen and he exci a ion magne ic ield is
gene a ed by an ex e nal sou ce using a co e coil o pe manen magne s [
28
,
29
]. He e,
he o o de ec is ep esen ed by a educed o missing magne ic lux ampli ude. Di ec
magne ic measu emen s ha e hei indispu able ad an ages, bu he echnology used is
qui e expensi e and equi es a good quali y measu emen sys em wi h as con e e s.
Addi ionally, Hall p obes a e e y agile o handling and he e is a isk o mechanical
damage in no mal echnological ope a ion.
The main mo i a ion is o ind and choose a sui able o -line me hod o o o diagnos-
ics. O e all, he diagnos ic sys em should be simple and loca ed in he o o manu ac u ing
p ocess be ween he die cas ing echnology and he ollowing ope a ions be o e he assem-
bly wi h he s a o . F om he e e ence li e a u e used [
28
,
30
], i is mo e o less e iden
ha he main e alua ion me hod o he iden i ica ion o o o de ec s is he cu en ly used
FFT analysis. Especially in he case o he use o FFT analysis, he diagnos ic pos in he
manu ac u ing company needs o be co e ed by a esea che o a pe son wi h a highe
quali ica ion. Howe e , such a solu ion is no possible in mass p oduc ion o o o s. This
Ene gies 2021,14, 6573 3 o 23
led us o he idea o ying o isualize he de ec o he es ed o o in a di e en way han
he abo e men ioned p ocedu es. The main aim o ou wo k is o p o ide he in o ma ion
abou he de ec o he manu ac u ed o o o he ope a o so ha he iden i ica ion o he
de ec is based on a g aphical pa e n. In addi ion, he li e a u e [
28
,
30
] also show he
ou pu s o p ac ical implemen a ion o measu emen sys ems ha can be used in p ac ice in
mass p oduc ion o o o s. Howe e , he e is no de ailed discussion o he use o 2-senso
measu emen s, which we belie e can p o ide new in o ma ion in o o diagnos ics.
The pape is o ganized as ollows. In Sec ion 2, he inding o a sui able echnique
o o -line o o diagnos ics is desc ibed and he a angemen o senso s o measu ing
o o de ec s is p oposed. The design o he senso s is also desc ibed. In Sec ion 3, a
nume ical simula ion o a 2D elec omagne ic model o he o o is pe o med and he
o e all unc ionali y o he p oposed measu emen sys em is alida ed. In Sec ion 4, he
cons uc ion o a es o o designed o simula e o o aul s is desc ibed. In Sec ion 5, he
p ocessing o he senso signals, hei handling, and analysis is desc ibed. In
Sec ion 6
,
measu emen s on a eal o o o an asynch onous mo o a e made and alida ion o
he measu emen esul s is pe o med. The discussion and conclusion is p esen ed in
Sec ions 7and 8.
2. Senso Con igu a ion and Measu emen Me hod
F om he poin o iew o simplici y, eliabili y, and sensi i i y, a senso whose basic
p inciple is based on Fa aday’s law o elec omagne ic induc ion was conside ed o o o
diagnos ics [
31
]. The magne izing yoke ha gene a es he s a ic magne ic ield is loca ed
nea he o o [
28
,
29
]. The magne ic ield lines om he exci a ion yoke a e closed by an
ai gap ac oss he o o ee h a ound he o o ba slo s. When he o o o a es, a ol age
is induced in he o o ba s. All he ba s a e sho -ci cui ed a bo h end- ings and hen
cu en lows h ough he o o ba s. This cu en c ea es i s magne ic ield and a ec s he
o iginal exci a ion s a ic ield.
The gene a ed esponse in he magne ic ield will also p oduce a ime change in he
magne ic lux. This change is de ec ed and a ol age is induced in he sensing coil. A
heal hy o o gene a es a egula pe iodic ol age wa e o m, while a de ec o o shows a
de o ma ion in he ol age wa e o m depending on he ype o aul . The magni ude and
shape o his ol age a e he e o e in di ec p opo ion o he physical s a e o he o o [
30
].
In he sea ch o a sui able a angemen , se e al possible designs and senso a angemen s
we e selec ed, see Figu e 1.
Ene gies 2021, 14, x FOR PEER REVIEW 3 o 24
pos in he manu ac u ing company needs o be co e ed by a esea che o a pe son wi h
a highe quali ica ion. Howe e , such a solu ion is no possible in mass p oduc ion o
o o s. This led us o he idea o ying o isualize he de ec o he es ed o o in a di -
e en way han he abo e men ioned p ocedu es. The main aim o ou wo k is o p o ide
he in o ma ion abou he de ec o he manu ac u ed o o o he ope a o so ha he
iden i ica ion o he de ec is based on a g aphical pa e n. In addi ion, he li e a u e
[28,30] also show he ou pu s o p ac ical implemen a ion o measu emen sys ems ha
can be used in p ac ice in mass p oduc ion o o o s. Howe e , he e is no de ailed dis-
cussion o he use o 2-senso measu emen s, which we belie e can p o ide new in o -
ma ion in o o diagnos ics.
The pape is o ganized as ollows. In Sec ion 2, he inding o a sui able echnique o
o -line o o diagnos ics is desc ibed and he a angemen o senso s o measu ing o o
de ec s is p oposed. The design o he senso s is also desc ibed. In Sec ion 3, a nume ical
simula ion o a 2D elec omagne ic model o he o o is pe o med and he o e all unc-
ionali y o he p oposed measu emen sys em is alida ed. In Sec ion 4, he cons uc ion
o a es o o designed o simula e o o aul s is desc ibed. In Sec ion 5, he p ocessing o
he senso signals, hei handling, and analysis is desc ibed. In Sec ion 6, measu emen s
on a eal o o o an asynch onous mo o a e made and alida ion o he measu emen
esul s is pe o med. The discussion and conclusion is p esen ed in Sec ions 7 and 8.
2. Senso Con igu a ion and Measu emen Me hod
F om he poin o iew o simplici y, eliabili y, and sensi i i y, a senso whose basic
p inciple is based on Fa aday’s law o elec omagne ic induc ion was conside ed o o o
diagnos ics [31]. The magne izing yoke ha gene a es he s a ic magne ic ield is loca ed
nea he o o [28,29]. The magne ic ield lines om he exci a ion yoke a e closed by an
ai gap ac oss he o o ee h a ound he o o ba slo s. When he o o o a es, a ol age
is induced in he o o ba s. All he ba s a e sho -ci cui ed a bo h end- ings and hen
cu en lows h ough he o o ba s. This cu en c ea es i s magne ic ield and a ec s he
o iginal exci a ion s a ic ield.
The gene a ed esponse in he magne ic ield will also p oduce a ime change in he
magne ic lux. This change is de ec ed and a ol age is induced in he sensing coil. A
heal hy o o gene a es a egula pe iodic ol age wa e o m, while a de ec o o shows a
de o ma ion in he ol age wa e o m depending on he ype o aul . The magni ude and
shape o his ol age a e he e o e in di ec p opo ion o he physical s a e o he o o
[30]. In he sea ch o a sui able a angemen , se e al possible designs and senso a -
angemen s we e selec ed, see Figu e 1.
(a)
(b)
(c)
Figu e 1. The selec ed design o ac i e senso s: (a) DC supply exci a ion; (b) wi h pe manen magne s posi ioned on he
yoke poles; (c) wi h a pe manen magne posi ioned in one pa o he yoke only.
Figu e 1a shows a senso exci ed by a DC cu en sou ce, Figu e 1b shows a senso
whe e exci a ion is p o ided by pe manen magne s glued o he poles o he senso ’s
magne ic ci cui , and inally Figu e 1c shows a a ian wi h a pe manen magne on one
pole o he senso . In all cases, he magne ic senso ci cui was made in a U-shape o
Figu e 1.
The selec ed design o ac i e senso s: (
a
) DC supply exci a ion; (
b
) wi h pe manen magne s posi ioned on he
yoke poles; (c) wi h a pe manen magne posi ioned in one pa o he yoke only.
Figu e 1a shows a senso exci ed by a DC cu en sou ce, Figu e 1b shows a senso
whe e exci a ion is p o ided by pe manen magne s glued o he poles o he senso ’s
magne ic ci cui , and inally Figu e 1c shows a a ian wi h a pe manen magne on one
pole o he senso . In all cases, he magne ic senso ci cui was made in a U-shape o simpli y
he handling o he sensing coil. Al hough such senso s a e qui e simple o manu ac u e,
Ene gies 2021,14, 6573 4 o 23
we ound a numbe o p oblems when aligning hem o he o o . These ac i e senso s
showed a high endency o ib a e due o he pulsa ing magne ic pull as he o o o a es.
To elimina e he ib a ions ans e ed o he sensing pa o he senso , we pa ially
sepa a e he exci a ion and sensing unc ions by di iding he senso in o 2 pieces, ac i e
and passi e. The ac i e senso con ains exci a ion pe manen magne s NdFeB ype N42. I s
sensing coil is placed longi udinal be ween he pole ex ensions and wound on an insula ing
co e ame. The coil con ains app oxima ely N = 150 u ns o insula ed wi e and is o ien ed
in he axis o o a ion. The pole ex ensions and he co e o he sensing coil a e assembled
om high g ade o ien ed elec o echnical shee M165-35. The ac i e senso assembly is
clamped wi h b ass sc ews be ween aluminum holde s, see Figu e 2.
Ene gies 2021, 14, x FOR PEER REVIEW 4 o 24
simpli y he handling o he sensing coil. Al hough such senso s a e qui e simple o
manu ac u e, we ound a numbe o p oblems when aligning hem o he o o . These
ac i e senso s showed a high endency o ib a e due o he pulsa ing magne ic pull as
he o o o a es.
To elimina e he ib a ions ans e ed o he sensing pa o he senso , we pa ially
sepa a e he exci a ion and sensing unc ions by di iding he senso in o 2 pieces, ac i e
and passi e. The ac i e senso con ains exci a ion pe manen magne s NdFeB ype N42.
I s sensing coil is placed longi udinal be ween he pole ex ensions and wound on an in-
sula ing co e ame. The coil con ains app oxima ely N = 150 u ns o insula ed wi e and
is o ien ed in he axis o o a ion. The pole ex ensions and he co e o he sensing coil a e
assembled om high g ade o ien ed elec o echnical shee M165-35. The ac i e senso
assembly is clamped wi h b ass sc ews be ween aluminum holde s, see Figu e 2.
Figu e 2. Design con igu a ion o he senso s—Ac i e senso wi h he sensing coil be ween pole
ex ende s and Passi e senso wi h wo coils con igu a ion.
The passi e senso in Figu e 2 consis s o a magne ic ci cui also made o o ien ed
shee s and ben in o a U-shape. Two sensing coils a e a ached o i s poles. Each o he
coils con ain app oxima ely N = 500 u ns o insula ed wi e and he wo coils a e elec i-
cally connec ed in se ies o inc ease he alue o he induced ol age. The passi e senso
assembly is ixed in a non-magne ic insula ing enclosu e.
The con igu a ion o he measu emen sys em shown in Figu e 3 was ound o be he
mos con enien om a p ac ical poin o iew. Iden i ica ion o o o aul s uses a com-
bina ion o ac i e and passi e senso s o a ed 90 deg ela i e o each o he . The ac i e
senso gene a es he necessa y s a ic magne izing ield and senses i s change as he o o
o a es. The passi e senso cap u es he s ay ield nea he o o su ace.
Figu e 2.
Design con igu a ion o he senso s—Ac i e senso wi h he sensing coil be ween pole
ex ende s and Passi e senso wi h wo coils con igu a ion.
The passi e senso in Figu e 2consis s o a magne ic ci cui also made o o ien ed
shee s and ben in o a U-shape. Two sensing coils a e a ached o i s poles. Each o
he coils con ain app oxima ely N = 500 u ns o insula ed wi e and he wo coils a e
elec ically connec ed in se ies o inc ease he alue o he induced ol age. The passi e
senso assembly is ixed in a non-magne ic insula ing enclosu e.
The con igu a ion o he measu emen sys em shown in Figu e 3was ound o be
he mos con enien om a p ac ical poin o iew. Iden i ica ion o o o aul s uses a
combina ion o ac i e and passi e senso s o a ed 90 deg ela i e o each o he . The ac i e
senso gene a es he necessa y s a ic magne izing ield and senses i s change as he o o
o a es. The passi e senso cap u es he s ay ield nea he o o su ace.
Ene gies 2021, 14, x FOR PEER REVIEW 5 o 24
Figu e 3. Basic con igu a ion o he measu ing sys em wi h wo independen senso s.
The ol age ou pu s o bo h senso s a e ed o a DAQ ca d connec ed o a compu e .
The measu ed ol ages a e hen adjus ed, ampli ied, il e ed, and p ocessed by so wa e.
The modi ied signals a e hen analyzed and displayed g aphically o he ope a o o
e alua e.
3. 2D FEM Elec omagne ic Simula ion
A 2D FEM elec omagne ic model was used as a basic ool o e i y he unc ionali y
o he designed o o measu emen sys em. In he ini ial phase, he FEM model was used
o ind he mos sui able a angemen o senso s and o de e mine hei op imal posi ions
and dimensions. The FEM model con ains a o o shee wi h slo s in which he o o ba s
a e placed in isola ion, see Figu e 4.
Figu e 4. 2D FEM model o he es o o assembly wi h mesh in he senso egions.
The ac i e senso is loca ed a he bo om, while he passi e senso is loca ed on he
igh along he di ec ion o o o o a ion. In he ai gap and o o ba egions, he model
is buil wi h a p ecision mesh o elimina e alse induced ol age wa e o ms due o poo
Figu e 3. Basic con igu a ion o he measu ing sys em wi h wo independen senso s.
Ene gies 2021,14, 6573 5 o 23
The ol age ou pu s o bo h senso s a e ed o a DAQ ca d connec ed o a compu e . The
measu ed ol ages a e hen adjus ed, ampli ied, il e ed, and p ocessed by so wa e. The
modi ied signals a e hen analyzed and displayed g aphically o he ope a o o e alua e.
3. 2D FEM Elec omagne ic Simula ion
A 2D FEM elec omagne ic model was used as a basic ool o e i y he unc ionali y
o he designed o o measu emen sys em. In he ini ial phase, he FEM model was used
o ind he mos sui able a angemen o senso s and o de e mine hei op imal posi ions
and dimensions. The FEM model con ains a o o shee wi h slo s in which he o o ba s
a e placed in isola ion, see Figu e 4.
Ene gies 2021, 14, x FOR PEER REVIEW 5 o 24
Figu e 3. Basic con igu a ion o he measu ing sys em wi h wo independen senso s.
The ol age ou pu s o bo h senso s a e ed o a DAQ ca d connec ed o a compu e .
The measu ed ol ages a e hen adjus ed, ampli ied, il e ed, and p ocessed by so wa e.
The modi ied signals a e hen analyzed and displayed g aphically o he ope a o o
e alua e.
3. 2D FEM Elec omagne ic Simula ion
A 2D FEM elec omagne ic model was used as a basic ool o e i y he unc ionali y
o he designed o o measu emen sys em. In he ini ial phase, he FEM model was used
o ind he mos sui able a angemen o senso s and o de e mine hei op imal posi ions
and dimensions. The FEM model con ains a o o shee wi h slo s in which he o o ba s
a e placed in isola ion, see Figu e 4.
Figu e 4. 2D FEM model o he es o o assembly wi h mesh in he senso egions.
The ac i e senso is loca ed a he bo om, while he passi e senso is loca ed on he
igh along he di ec ion o o o o a ion. In he ai gap and o o ba egions, he model
is buil wi h a p ecision mesh o elimina e alse induced ol age wa e o ms due o poo
Figu e 4. 2D FEM model o he es o o assembly wi h mesh in he senso egions.
The ac i e senso is loca ed a he bo om, while he passi e senso is loca ed on he
igh along he di ec ion o o o o a ion. In he ai gap and o o ba egions, he model
is buil wi h a p ecision mesh o elimina e alse induced ol age wa e o ms due o poo
disc e iza ion. The FEM model con ains app oxima ely 60,000 elemen s and ansien ime
analysis was used o sol e he model.
The elec omagne ic model was sol ed in Ansys Maxwell, which also allows o de ine
an ex e nal elec ical ci cui wi h a di ec link o he elec omagne ic FEM model. The
ex e nal ci cui was used o desc ibe he squi el cage o he o o , see Figu e 5.
The ci cui diag am is ully enclosed and consis s o induc ances and esis ances. The
ci cui elemen s a e a anged o ep esen he elec ical coupling o he o o ba s (Rbx,
Lbx) wi h he end- ing segmen s (Re _xy, Le _xy) [
32
,
33
]. By changing he alues o he
ci cui elemen s, he cha ac e is ics o he ba s and end- ings can be desc ibed in he case o
a simula ed aul , e.g., a b oken ba , a ing segmen wi h educed conduc i i y, o o e all a
combina ion o aul s.
As he o o o a es, he cu en s in he ba s c ea e a eac ion ield ha dis o s he
o iginally symme ical ield o he magne iza ion yoke. Figu e 6shows he magne ic ield
dis ibu ion in he o o as he aul y ba passes by he wo senso s.
The aul y ba is shown he e in black colo . No ol age is induced in his b oken ba
and he cu en alue Iba = 0 A. No eac ion lux is hen gene a ed in he su oundings o
he ba and a pa o he magne ic lux passes h ough he adjacen oo h. A his poin , a
de o ma ion occu s in he o al magne ic ield, which is cap u ed by he sensing coil o he
ac i e senso and also by he coil o he passi e senso .

Ene gies 2021,14, 6573 6 o 23
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disc e iza ion. The FEM model con ains app oxima ely 60,000 elemen s and ansien
ime analysis was used o sol e he model.
The elec omagne ic model was sol ed in Ansys Maxwell, which also allows o de-
ine an ex e nal elec ical ci cui wi h a di ec link o he elec omagne ic FEM model. The
ex e nal ci cui was used o desc ibe he squi el cage o he o o , see Figu e 5.
Figu e 5. Equi alen elec ical ci cui o he o o cage.
The ci cui diag am is ully enclosed and consis s o induc ances and esis ances.
The ci cui elemen s a e a anged o ep esen he elec ical coupling o he o o ba s
(Rbx, Lbx) wi h he end- ing segmen s (Re _xy, Le _xy) [32,33]. By changing he alues o
he ci cui elemen s, he cha ac e is ics o he ba s and end- ings can be desc ibed in he
case o a simula ed aul , e.g., a b oken ba , a ing segmen wi h educed conduc i i y, o
o e all a combina ion o aul s.
As he o o o a es, he cu en s in he ba s c ea e a eac ion ield ha dis o s he
o iginally symme ical ield o he magne iza ion yoke. Figu e 6 shows he magne ic ield
dis ibu ion in he o o as he aul y ba passes by he wo senso s.
Figu e 6. Magne ic lux densi y dis ibu ion on he 2D FEM model o he es o o assembly.
The aul y ba is shown he e in black colo . No ol age is induced in his b oken ba
and he cu en alue Iba = 0 A. No eac ion lux is hen gene a ed in he su oundings o
he ba and a pa o he magne ic lux passes h ough he adjacen oo h. A his poin , a
Figu e 5. Equi alen elec ical ci cui o he o o cage.
Ene gies 2021, 14, x FOR PEER REVIEW 6 o 24
disc e iza ion. The FEM model con ains app oxima ely 60,000 elemen s and ansien
ime analysis was used o sol e he model.
The elec omagne ic model was sol ed in Ansys Maxwell, which also allows o de-
ine an ex e nal elec ical ci cui wi h a di ec link o he elec omagne ic FEM model. The
ex e nal ci cui was used o desc ibe he squi el cage o he o o , see Figu e 5.
Figu e 5. Equi alen elec ical ci cui o he o o cage.
The ci cui diag am is ully enclosed and consis s o induc ances and esis ances.
The ci cui elemen s a e a anged o ep esen he elec ical coupling o he o o ba s
(Rbx, Lbx) wi h he end- ing segmen s (Re _xy, Le _xy) [32,33]. By changing he alues o
he ci cui elemen s, he cha ac e is ics o he ba s and end- ings can be desc ibed in he
case o a simula ed aul , e.g., a b oken ba , a ing segmen wi h educed conduc i i y, o
o e all a combina ion o aul s.
As he o o o a es, he cu en s in he ba s c ea e a eac ion ield ha dis o s he
o iginally symme ical ield o he magne iza ion yoke. Figu e 6 shows he magne ic ield
dis ibu ion in he o o as he aul y ba passes by he wo senso s.
Figu e 6. Magne ic lux densi y dis ibu ion on he 2D FEM model o he es o o assembly.
The aul y ba is shown he e in black colo . No ol age is induced in his b oken ba
and he cu en alue Iba = 0 A. No eac ion lux is hen gene a ed in he su oundings o
he ba and a pa o he magne ic lux passes h ough he adjacen oo h. A his poin , a
Figu e 6. Magne ic lux densi y dis ibu ion on he 2D FEM model o he es o o assembly.
When he o o is o a ed by 90 deg, he b oken ba eaches he passi e senso . He e,
he magne ic lux lines a e locally closed h ough a egion ac oss he o o ee h ha
su ound he aul y ba and he con ac b idge o he closed slo . This local dis o ion o
he magne ic lux eappea s in he s ay ield and is again de ec ed by he passi e senso .
The induced ol age wa e o ms on he sensing coils o he ac i e and passi e senso s
o he FEM model a e shown in Figu e 7a. A ime window = (0.4–1.0) s is selec ed o
plo ing, whe e he ol age wa e o ms a e in s eady s a e al eady. The wa e o ms a e o se
in he g aph o a oid o e lapping and o make hem clea e . The ed colo co esponds o
he induced ol age o he ac i e senso , he blue colo o he induced ol age on he passi e
senso . The ol age ange o bo h signals is also no malized in he in e al (
−
1,1). The
ime wa e o m o bo h ol ages is no pu e sinusoidal bu shows a shape de o ma ion. The
de o ma ion is mo e isible in he ol age wa e o m o he passi e senso . A heal hy o o
wi hou de ec s shows a egula wa e o m o bo h induced ol ages wi hou de ia ions.
Figu e 7b shows he FFT analysis o bo h senso signals. The no malized ampli ude
spec um is shown, whe e he equency x = 84 Hz isibly domina es. The alue o his
equency co esponds o he se o o o a ion speed n = 180 pm and he numbe o i s
slo s (ba s) Nd = 28. The sidebands also appea and do no exceed he alue o
−
40 dB in
ampli ude. The sidebands a e much mo e signi ican in a passi e senso .
Ene gies 2021,14, 6573 7 o 23
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de o ma ion occu s in he o al magne ic ield, which is cap u ed by he sensing coil o
he ac i e senso and also by he coil o he passi e senso .
When he o o is o a ed by 90 deg, he b oken ba eaches he passi e senso . He e,
he magne ic lux lines a e locally closed h ough a egion ac oss he o o ee h ha
su ound he aul y ba and he con ac b idge o he closed slo . This local dis o ion o
he magne ic lux eappea s in he s ay ield and is again de ec ed by he passi e senso .
The induced ol age wa e o ms on he sensing coils o he ac i e and passi e sen-
so s o he FEM model a e shown in Figu e 7a. A ime window = (0.4–1.0) s is selec ed
o plo ing, whe e he ol age wa e o ms a e in s eady s a e al eady. The wa e o ms a e
o se in he g aph o a oid o e lapping and o make hem clea e . The ed colo co e-
sponds o he induced ol age o he ac i e senso , he blue colo o he induced ol age
on he passi e senso . The ol age ange o bo h signals is also no malized in he in e al
(−1,1). The ime wa e o m o bo h ol ages is no pu e sinusoidal bu shows a shape de-
o ma ion. The de o ma ion is mo e isible in he ol age wa e o m o he passi e senso .
A heal hy o o wi hou de ec s shows a egula wa e o m o bo h induced ol ages
wi hou de ia ions. Figu e 7b shows he FFT analysis o bo h senso signals. The no -
malized ampli ude spec um is shown, whe e he equency x = 84 Hz isibly domina es.
The alue o his equency co esponds o he se o o o a ion speed n = 180 pm and
he numbe o i s slo s (ba s) Nd = 28. The sidebands also appea and do no exceed he
alue o −40 dB in ampli ude. The sidebands a e much mo e signi ican in a passi e
senso .
(a)
(b)
Figu e 7. FEM model o a heal hy o o wi hou any de ec s: (a) no malized wa e o ms o he induced ol ages in he
senso s; (b) FFT analysis o induced ol age wa e o ms.
Figu e 8a shows he induced ol age wa e o ms o he FEM simula ion o 1 b oken
ba . The e is a egion on he induced ol age wa e o m o he ac i e senso whe e pa o
i is comple ely missing (g een a ow). This emp y egion is pe iodically epea ed a he
same ime in e als as he o o o a es. This indica es a aul in he ba , whe e he ol age
is induced, bu no elec ic cu en lows h ough he ba due o he missing elec ical
connec ion o he end- ing. The lack o a eac i e magne ic lux will c ea e a signi ican
dis o ion in he o he wise egula ol age wa e o m on he ac i e senso . On he ol age
wa e o m o he passi e senso , he in o ma ion abou he b oken o o ba appea s a
he same ime poin as o he ac i e senso ( 1 = 480 ms). Howe e , he ol age wa e o m
is di e en on he passi e senso due o i s di e en design na u e. Wi h a ime delay o
abou Δ = 85 ms (in ime 2 = 565 ms), he in o ma ion abou he b oken ba eappea s by
he oscilla ion o he induced ol age on he passi e senso . This is he poin a which he
b oken ba is close o he passi e senso and he o o has o a ed 90 deg (+7 ba dis-
placemen ).
Figu e 7.
FEM model o a heal hy o o wi hou any de ec s: (
a
) no malized wa e o ms o he induced ol ages in he
senso s; (b) FFT analysis o induced ol age wa e o ms.
Figu e 8a shows he induced ol age wa e o ms o he FEM simula ion o 1 b oken
ba . The e is a egion on he induced ol age wa e o m o he ac i e senso whe e pa
o i is comple ely missing (g een a ow). This emp y egion is pe iodically epea ed
a he same ime in e als as he o o o a es. This indica es a aul in he ba , whe e
he ol age is induced, bu no elec ic cu en lows h ough he ba due o he missing
elec ical connec ion o he end- ing. The lack o a eac i e magne ic lux will c ea e a
signi ican dis o ion in he o he wise egula ol age wa e o m on he ac i e senso . On
he ol age wa e o m o he passi e senso , he in o ma ion abou he b oken o o ba
appea s a he same ime poin as o he ac i e senso ( 1 = 480 ms). Howe e , he ol age
wa e o m is di e en on he passi e senso due o i s di e en design na u e. Wi h a ime
delay o abou
∆
= 85 ms (in ime 2 = 565 ms), he in o ma ion abou he b oken ba
eappea s by he oscilla ion o he induced ol age on he passi e senso . This is he poin
a which he b oken ba is close o he passi e senso and he o o has o a ed 90 deg
(+7 ba displacemen ).
Ene gies 2021, 14, x FOR PEER REVIEW 8 o 24
(a)
(b)
Figu e 8. FEM model o a o o wi h a b oken ba : (a) no malized wa e o ms o he induced ol ages in he senso s; (b)
FFT analysis o induced ol age wa e o ms.
Figu e 8b shows he FFT analysis o he ol ages o bo h senso s. In addi ion o he
main ha monic x = 84 Hz, he e a e signi ican sidebands wi h a equency sepa a ion o
Δ = 3 Hz indica ing a ba aul . Fo he ac i e senso , he signal o se is app oxima ely
−24 dB. The passi e senso is mo e sensi i e due o he wo de ec ed dis o ions and he
o se om he main ha monic is less han −18 dB.
In he FEM simula ion o a b oken end- ing segmen be ween he ba s, his de ec
again p esen s simila ly on bo h senso induced ol age wa e o ms. I can be seen in
Figu e 9a ha he b oken segmen be ween he ba s causes mul iple oscilla ions jus as i
passes o e he exci a ion poles o he ac i e senso . The wa e o m is hen u he de-
o med in ime by he DC componen .
(a)
(b)
Figu e 9. FEM model o a o o wi h a b oken end- ing segmen : (a) no malized wa e o ms o he induced ol ages in he
senso s; (b) FFT analysis o induced ol age wa e o ms.
A segmen ailu e is epea edly isible on he induced ol age wa e o m o he
passi e senso , simila o he case o a b oken ba . The in o ma ion abou he aul y
segmen is a he same ime ins an as o he ac i e senso ( 1 = 480 ms). I appea s as an
oscilla ion and a signi ican wa e o m dis o ion. Then, he ampli ude o he oscilla ion
dec eases and hen slowly inc eases un il he aul y segmen (2 adjacen ba s wi h a
aul y segmen ) is close o he passi e senso . He e again, he ampli ude o he induced
Figu e 8.
FEM model o a o o wi h a b oken ba : (
a
) no malized wa e o ms o he induced ol ages in he senso s; (
b
) FFT
analysis o induced ol age wa e o ms.
Figu e 8b shows he FFT analysis o he ol ages o bo h senso s. In addi ion o he
main ha monic x = 84 Hz, he e a e signi ican sidebands wi h a equency sepa a ion o
∆
= 3 Hz indica ing a ba aul . Fo he ac i e senso , he signal o se is app oxima ely
Ene gies 2021,14, 6573 8 o 23
−
24 dB. The passi e senso is mo e sensi i e due o he wo de ec ed dis o ions and he
o se om he main ha monic is less han −18 dB.
In he FEM simula ion o a b oken end- ing segmen be ween he ba s, his de ec
again p esen s simila ly on bo h senso induced ol age wa e o ms. I can be seen in
Figu e 9a ha he b oken segmen be ween he ba s causes mul iple oscilla ions jus as i
passes o e he exci a ion poles o he ac i e senso . The wa e o m is hen u he de o med
in ime by he DC componen .
Ene gies 2021, 14, x FOR PEER REVIEW 8 o 24
(a)
(b)
Figu e 8. FEM model o a o o wi h a b oken ba : (a) no malized wa e o ms o he induced ol ages in he senso s; (b)
FFT analysis o induced ol age wa e o ms.
Figu e 8b shows he FFT analysis o he ol ages o bo h senso s. In addi ion o he
main ha monic x = 84 Hz, he e a e signi ican sidebands wi h a equency sepa a ion o
Δ = 3 Hz indica ing a ba aul . Fo he ac i e senso , he signal o se is app oxima ely
−24 dB. The passi e senso is mo e sensi i e due o he wo de ec ed dis o ions and he
o se om he main ha monic is less han −18 dB.
In he FEM simula ion o a b oken end- ing segmen be ween he ba s, his de ec
again p esen s simila ly on bo h senso induced ol age wa e o ms. I can be seen in
Figu e 9a ha he b oken segmen be ween he ba s causes mul iple oscilla ions jus as i
passes o e he exci a ion poles o he ac i e senso . The wa e o m is hen u he de-
o med in ime by he DC componen .
(a)
(b)
Figu e 9. FEM model o a o o wi h a b oken end- ing segmen : (a) no malized wa e o ms o he induced ol ages in he
senso s; (b) FFT analysis o induced ol age wa e o ms.
A segmen ailu e is epea edly isible on he induced ol age wa e o m o he
passi e senso , simila o he case o a b oken ba . The in o ma ion abou he aul y
segmen is a he same ime ins an as o he ac i e senso ( 1 = 480 ms). I appea s as an
oscilla ion and a signi ican wa e o m dis o ion. Then, he ampli ude o he oscilla ion
dec eases and hen slowly inc eases un il he aul y segmen (2 adjacen ba s wi h a
aul y segmen ) is close o he passi e senso . He e again, he ampli ude o he induced
Figu e 9.
FEM model o a o o wi h a b oken end- ing segmen : (
a
) no malized wa e o ms o he induced ol ages in he
senso s; (b) FFT analysis o induced ol age wa e o ms.
A segmen ailu e is epea edly isible on he induced ol age wa e o m o he passi e
senso , simila o he case o a b oken ba . The in o ma ion abou he aul y segmen is a
he same ime ins an as o he ac i e senso ( 1 = 480 ms). I appea s as an oscilla ion and a
signi ican wa e o m dis o ion. Then, he ampli ude o he oscilla ion dec eases and hen
slowly inc eases un il he aul y segmen (2 adjacen ba s wi h a aul y segmen ) is close o
he passi e senso . He e again, he ampli ude o he induced ol age inc eases suddenly
(
2 = 565 ms
). Figu e 9b shows he FFT analysis o he ol ages o bo h senso s. Wi h he
main ha monic x = 84 Hz, signi ican sidebands wi h equency spacing
∆ =3Hz
appea .
Fo he ac i e senso , he sideband is concen a ed a ound he main ha monic and also
a ound he equency 2 = 28 Hz, which co esponds o he numbe o o o slo s. In a
passi e senso , he sidebands a e dis ibu ed o e he en i e displayed equency ange
(0–125 Hz). The lowes alue o he o se signal is in he o de o −21 dB.
The 2D FEM nume ical model desc ibes he p oblem only in he plane o he o o
sec ion and hus is no able o p o ide all he ele an in o ma ion, such as he o o slo
skew, he dis ibu ion o de ec s in he ba along he leng h, he axial o a ion o he senso s,
e c. The FEM simula ion o he induced ol age wa e o ms on he senso s showed ha he
basic p inciple o he designed induc i e senso s wo ks eliably. The measu emen sys em
is able o de ec a wide ange o o o manu ac u ing de ec s wi h su icien esolu ion.
Wi h he help o he pe o med elec omagne ic ield simula ions, he op imum loca ions
o senso placemen we e ound and also he op imiza ion o he ac i e and passi e senso
design was ealized.
4. Tes Ro o Assembly and Adjus men o Ro o Faul Ve i ica ion
To e i y he designed measu emen echnique and FEM simula ions, a es o o was
manu ac u ed. The es o o consis s o high g ade non-o ien ed elec o echnical shee s
ype M530-65A wi h hickness h = 0.65 mm and o al leng h o packe L = 150 mm. The
shee con ains Nd = 28 closed slo s in o which he b ass o o ba s a e inse ed. The o o
Ene gies 2021,14, 6573 9 o 23
shee s a e no p ocessed in any echnological way be o e assembling in o a packe and
we e andomly selec ed om he con aine o he cu ing machine.
The o o ba s a e made o b ass wi h a diame e o d = 4 mm and a e h eaded a
bo h ends. The end- ings a e milled om coppe shee wi h a hickness o 2 mm. All o o
ba s a e insula ed in he o o slo s by using insula ing ubes. Simila ly, he end- ings a e
sepa a ed om he o o by an insula ing pla e and a e no elec ically connec ed o he
o o shee s. Figu e 10 shows he indi idual pa s o he o o be o e i is assembled and
pa ial iew o he manu ac u ed es o o .
Ene gies 2021, 14, x FOR PEER REVIEW 9 o 24
ol age inc eases suddenly ( 2 = 565 ms). Figu e 9b shows he FFT analysis o he ol ages
o bo h senso s. Wi h he main ha monic x = 84 Hz, signi ican sidebands wi h equency
spacing Δ = 3 Hz appea . Fo he ac i e senso , he sideband is concen a ed a ound he
main ha monic and also a ound he equency 2 = 28 Hz, which co esponds o he
numbe o o o slo s. In a passi e senso , he sidebands a e dis ibu ed o e he en i e
displayed equency ange (0–125 Hz). The lowes alue o he o se signal is in he o de
o −21 dB.
The 2D FEM nume ical model desc ibes he p oblem only in he plane o he o o
sec ion and hus is no able o p o ide all he ele an in o ma ion, such as he o o slo
skew, he dis ibu ion o de ec s in he ba along he leng h, he axial o a ion o he sen-
so s, e c. The FEM simula ion o he induced ol age wa e o ms on he senso s showed
ha he basic p inciple o he designed induc i e senso s wo ks eliably. The measu e-
men sys em is able o de ec a wide ange o o o manu ac u ing de ec s wi h su icien
esolu ion. Wi h he help o he pe o med elec omagne ic ield simula ions, he op i-
mum loca ions o senso placemen we e ound and also he op imiza ion o he ac i e
and passi e senso design was ealized.
4. Tes Ro o Assembly and Adjus men o Ro o Faul Ve i ica ion
To e i y he designed measu emen echnique and FEM simula ions, a es o o
was manu ac u ed. The es o o consis s o high g ade non-o ien ed elec o echnical
shee s ype M530-65A wi h hickness h = 0.65 mm and o al leng h o packe L = 150 mm.
The shee con ains Nd = 28 closed slo s in o which he b ass o o ba s a e inse ed. The
o o shee s a e no p ocessed in any echnological way be o e assembling in o a packe
and we e andomly selec ed om he con aine o he cu ing machine.
The o o ba s a e made o b ass wi h a diame e o d = 4 mm and a e h eaded a
bo h ends. The end- ings a e milled om coppe shee wi h a hickness o 2 mm. All o o
ba s a e insula ed in he o o slo s by using insula ing ubes. Simila ly, he end- ings a e
sepa a ed om he o o by an insula ing pla e and a e no elec ically connec ed o he
o o shee s. Figu e 10 shows he indi idual pa s o he o o be o e i is assembled and
pa ial iew o he manu ac u ed es o o .
Figu e 10. The es o o se wi h indi idual componen s.
The o o ba s a e ixed o he end- ings wi h nu s. The o e all o o a angemen
was chosen o make aul simula ion easie . The o o allows es ing, o example, a
change in he conduc i i y o he end- ing, a b eak in he end- ing o pa o he end- ing,
a educed conduc i i y o he ba , a b oken o o ba o a combina ion o hese aul s. A
basic o o measu ing se up wi h senso a angemen is shown in Figu e 11.
Figu e 10. The es o o se wi h indi idual componen s.
The o o ba s a e ixed o he end- ings wi h nu s. The o e all o o a angemen was
chosen o make aul simula ion easie . The o o allows es ing, o example, a change in
he conduc i i y o he end- ing, a b eak in he end- ing o pa o he end- ing, a educed
conduc i i y o he ba , a b oken o o ba o a combina ion o hese aul s. A basic o o
measu ing se up wi h senso a angemen is shown in Figu e 11.
Ene gies 2021, 14, x FOR PEER REVIEW 10 o 24
Figu e 11. O e all iew o he measu ing sys em wi h es o o .
The o o o a ion is ensu ed by he NEMA17 s epped mo o ope a ed by a d i e
ia he A duino module. The mo o o a ion speed is ixed o n = 180 pm (3 ps), and i
needs abou 10 s o each he se speed in linea accele a ion mode. The s epped mo o is
a ached o he o o by iming pulleys and a ubbe iming bel o elimina e he mo o
ib a ions as well as o ensu e exac e olu ion wi hou slip. The sha wi h he es o o
is placed in bea ing housing.
Figu e 12 shows selec ed modi ica ions o he es o o end- ing o simula e i s
ailu e. Figu e 12 shows he se -up o simula ing he conduc i i y o he ing. He e, he
o iginal solid c oss-sec ion o he end- ing is eplaced by a se o coppe pla es. The
numbe o shee s de e mines he inal alue o he conduc i i y. Figu e 12 also shows a
simula ion o a b oken segmen o he end- ing be ween he ba s. The ai gap causes a
disconnec ion o he ini ially solid ing. The o o ba s emain conduc i ely connec ed o
he es o he ing.
Figu e 12. Cons uc ion adjus men s o he es o o wi h o e all ing conduc i i y dec ease and
disconnec ing in he end- ing segmen be ween he ba s.
To simula e he de ec s o he o o ba s, geome ic modi ica ions we e made o hei
c oss-sec ion as shown in Figu e 13. Many o he au ho s [18,21,27] use di ec d illing o
o o ba s o c ea e a de ec . In ou case, he educ ion o he ac i e c oss-sec ion o he ba
is achie ed by u ning he c oss-sec ion a abou 1/5 o i s o al leng h. The ba s so p e-
pa ed a e sequen ially inse ed in o he slo and he e ec o he conduc i i y d op can be
measu ed.
Figu e 11. O e all iew o he measu ing sys em wi h es o o .
The o o o a ion is ensu ed by he NEMA17 s epped mo o ope a ed by a d i e ia
he A duino module. The mo o o a ion speed is ixed o n = 180 pm (3 ps), and i needs
abou 10 s o each he se speed in linea accele a ion mode. The s epped mo o is a ached
o he o o by iming pulleys and a ubbe iming bel o elimina e he mo o ib a ions as
well as o ensu e exac e olu ion wi hou slip. The sha wi h he es o o is placed in
bea ing housing.
Figu e 12 shows selec ed modi ica ions o he es o o end- ing o simula e i s ailu e.
Figu e 12 shows he se -up o simula ing he conduc i i y o he ing. He e, he o iginal
solid c oss-sec ion o he end- ing is eplaced by a se o coppe pla es. The numbe o
shee s de e mines he inal alue o he conduc i i y. Figu e 12 also shows a simula ion o
a b oken segmen o he end- ing be ween he ba s. The ai gap causes a disconnec ion o
he ini ially solid ing. The o o ba s emain conduc i ely connec ed o he es o he ing.
Ene gies 2021,14, 6573 16 o 23
Figu e 22 shows he change in he o e all de o ma ion o he o al pa e n when a
ailu e occu s in a segmen o he end- ing. The change in he conduc i i y o he connec ion
be ween he wo ba s o he ini ially sepa a ed segmen was simula ed. As he conduc i i y
o he segmen dec eases, he p opo ions o he o al emain almos iden ical, bu i s
inclina ion in he symme y longi udinal axis changes signi ican ly. Wi h a ully b oken
segmen be ween he ba s, see Figu e 22d, he plo ing poin mo es along a se o ellip ic
cu es ha a e o a ed ela i e o each o he . The measu emen sensi i i y is lowe in his
case, which is also e iden om he FFT analysis o he spec a. This aul is be e isible
in he passi e senso , which shows a as e inc ease in sideband ampli udes.
Ene gies 2021, 14, x FOR PEER REVIEW 17 o 24
Figu e 21. Compa ison o FFT and o al pa e ns o he selec ed numbe o b oken ba s: (a)
Re e ence o al pa e n o o o wi hou de ec ; (b) 1 B oken ba ; (c) 2 B oken ba s; (d) 3 B oken
ba s.
Figu e 22 shows he change in he o e all de o ma ion o he o al pa e n when a
ailu e occu s in a segmen o he end- ing. The change in he conduc i i y o he con-
nec ion be ween he wo ba s o he ini ially sepa a ed segmen was simula ed. As he
conduc i i y o he segmen dec eases, he p opo ions o he o al emain almos iden i-
cal, bu i s inclina ion in he symme y longi udinal axis changes signi ican ly. Wi h a
ully b oken segmen be ween he ba s, see Figu e 22d, he plo ing poin mo es along a
se o ellip ic cu es ha a e o a ed ela i e o each o he . The measu emen sensi i i y is
lowe in his case, which is also e iden om he FFT analysis o he spec a. This aul is
be e isible in he passi e senso , which shows a as e inc ease in sideband ampli udes.
Figu e 22.
Compa ison o FFT and o al pa e ns o ailu es in segmen o end- ing: (
a
) Re e -
ence o al pa e n o o o wi hou de ec ; (
b
) 33% C oss-Sec ion Loss; (
c
) 67% C oss-Sec ion Loss;
(d) 100% C oss-Sec ion Loss.

Ene gies 2021,14, 6573 17 o 23
Combined o o ailu es a e shown in Figu e 23. A b oken ba in combina ion wi h a
b oken segmen o he end- ing o mul iple ailu es such as 2 b oken ba s wi h a b oken
segmen , e c., cause signi ican de o ma ion o he o iginally smoo h o al pa e n. The
plo ing poin g adually sepa a es om he o iginal o al pa e n in mul iple sequen ial
s eps. The pa e ns also il and o m in e nal loops. Thei inal o m is in ac a composi e
o he pa e ns ypical o he elemen a y aul s in Figu es 21 and 22. The sidebands in
he FFT analysis comple ely ill he space o he le and igh o he dominan ha monic
x = 84 Hz and illus a e he signi icance o he aul simula ed on he es o o .
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Figu e 22. Compa ison o FFT and o al pa e ns o ailu es in segmen o end- ing: (a) Re e ence
o al pa e n o o o wi hou de ec ; (b) 33% C oss-Sec ion Loss; (c) 67% C oss-Sec ion Loss; (d)
100% C oss-Sec ion Loss.
Combined o o ailu es a e shown in Figu e 23. A b oken ba in combina ion wi h a
b oken segmen o he end- ing o mul iple ailu es such as 2 b oken ba s wi h a b oken
segmen , e c., cause signi ican de o ma ion o he o iginally smoo h o al pa e n. The
plo ing poin g adually sepa a es om he o iginal o al pa e n in mul iple sequen ial
s eps. The pa e ns also il and o m in e nal loops. Thei inal o m is in ac a composi e
o he pa e ns ypical o he elemen a y aul s in Figu es 21 and 22. The sidebands in he
FFT analysis comple ely ill he space o he le and igh o he dominan ha monic x =
84 Hz and illus a e he signi icance o he aul simula ed on he es o o .
Figu e 23. Compa ison o FFT and o al pa e ns o combined o o ailu es: (a) 1 b oken ba + 1
b oken end- ing segmen ; (b) 1 b oken ba + 2 b oken end- ing segmen s; (c) 2 b oken ba s + 1
b oken end- ing segmen .
6. O -Line Measu emen o Real Squi el Cage Ro o s a e Cas ing P ocess
The designed measu emen p ocedu e and senso con igu a ion was e i ied on
se e al eal o o p o o ypes. Figu e 24 shows he basic a angemen o he measu emen
sys em wi h he o o ixed be ween he aluminum conical cen e ing ips. Figu e 24 also
Figu e 23.
Compa ison o FFT and o al pa e ns o combined o o ailu es: (
a
)
1 b oken ba + 1 b oken
end- ing segmen ; (
b
) 1 b oken ba + 2 b oken end- ing segmen s; (
c
) 2 b oken ba s + 1 b oken end- ing
segmen .
6. O -Line Measu emen o Real Squi el Cage Ro o s a e Cas ing P ocess
The designed measu emen p ocedu e and senso con igu a ion was e i ied on
se e al eal o o p o o ypes. Figu e 24 shows he basic a angemen o he measu emen
sys em wi h he o o ixed be ween he aluminum conical cen e ing ips. Figu e 24 also
shows ep esen a i e o o samples p epa ed o de ec de ec ion. The o o samples a e
unmachined, wi hou sha s, and we e collec ed a e cas ing and cooling.
Ene gies 2021,14, 6573 18 o 23
Ene gies 2021, 14, x FOR PEER REVIEW 19 o 24
shows ep esen a i e o o samples p epa ed o de ec de ec ion. The o o samples a e
unmachined, wi hou sha s, and we e collec ed a e cas ing and cooling.
Figu e 24. Measu emen sys em o eal o o es ing.
Measu emen s we e in gene al he same as in he p e ious es o o . Howe e , he
main ask was di e en and was o use he isualized o al pa e n o de e mine he aul
in he end- ing o o o ba s. Mos o he es ed o o s ep esen ed by sample R1 dis-
played a pa e n simila o ha shown in Figu e 25. The o al shape is ela i ely smoo h,
i s hickness being a ec ed by eccen ici y. FFT analysis indica es only a hin sideband
concen a ed a ound he dominan ha monic x = 84 Hz. The measu ed p o o ype o o s
con ain Nd = 20 ully closed slo s, and he pm had o be se highe han he es o o .
The equency band o se hus eaches Δ = 4.2 Hz.
Figu e 25. Ou pu s o a o o R1 (no de ec ).
In he g oup o o o s, a sample labeled R2 was ound ha showed a di e en o al
shape, see Figu e 26. FFT analysis indica ed he appea ance o a sideband in he lowe
equency ange. The o al pa e n is sepa a ed and he plo ing poin ci cula es along
mu ually il ed ellip ical shapes. F om his ou pu , we assumed ha his is a aul in he
end- ing.
Figu e 24. Measu emen sys em o eal o o es ing.
Measu emen s we e in gene al he same as in he p e ious es o o . Howe e ,
he main ask was di e en and was o use he isualized o al pa e n o de e mine he
aul in he end- ing o o o ba s. Mos o he es ed o o s ep esen ed by sample R1
displayed a pa e n simila o ha shown in Figu e 25. The o al shape is ela i ely smoo h,
i s hickness being a ec ed by eccen ici y. FFT analysis indica es only a hin sideband
concen a ed a ound he dominan ha monic x = 84 Hz. The measu ed p o o ype o o s
con ain
Nd = 20
ully closed slo s, and he pm had o be se highe han he es o o .
The equency band o se hus eaches ∆ = 4.2 Hz.
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shows ep esen a i e o o samples p epa ed o de ec de ec ion. The o o samples a e
unmachined, wi hou sha s, and we e collec ed a e cas ing and cooling.
Figu e 24. Measu emen sys em o eal o o es ing.
Measu emen s we e in gene al he same as in he p e ious es o o . Howe e , he
main ask was di e en and was o use he isualized o al pa e n o de e mine he aul
in he end- ing o o o ba s. Mos o he es ed o o s ep esen ed by sample R1 dis-
played a pa e n simila o ha shown in Figu e 25. The o al shape is ela i ely smoo h,
i s hickness being a ec ed by eccen ici y. FFT analysis indica es only a hin sideband
concen a ed a ound he dominan ha monic x = 84 Hz. The measu ed p o o ype o o s
con ain Nd = 20 ully closed slo s, and he pm had o be se highe han he es o o .
The equency band o se hus eaches Δ = 4.2 Hz.
Figu e 25. Ou pu s o a o o R1 (no de ec ).
In he g oup o o o s, a sample labeled R2 was ound ha showed a di e en o al
shape, see Figu e 26. FFT analysis indica ed he appea ance o a sideband in he lowe
equency ange. The o al pa e n is sepa a ed and he plo ing poin ci cula es along
mu ually il ed ellip ical shapes. F om his ou pu , we assumed ha his is a aul in he
end- ing.
Figu e 25. Ou pu s o a o o R1 (no de ec ).
In he g oup o o o s, a sample labeled R2 was ound ha showed a di e en o al
shape, see Figu e 26. FFT analysis indica ed he appea ance o a sideband in he lowe
equency ange. The o al pa e n is sepa a ed and he plo ing poin ci cula es along
mu ually il ed ellip ical shapes. F om his ou pu , we assumed ha his is a aul in
he end- ing.
Ene gies 2021, 14, x FOR PEER REVIEW 19 o 24
shows ep esen a i e o o samples p epa ed o de ec de ec ion. The o o samples a e
unmachined, wi hou sha s, and we e collec ed a e cas ing and cooling.
Figu e 24. Measu emen sys em o eal o o es ing.
Measu emen s we e in gene al he same as in he p e ious es o o . Howe e , he
main ask was di e en and was o use he isualized o al pa e n o de e mine he aul
in he end- ing o o o ba s. Mos o he es ed o o s ep esen ed by sample R1 dis-
played a pa e n simila o ha shown in Figu e 25. The o al shape is ela i ely smoo h,
i s hickness being a ec ed by eccen ici y. FFT analysis indica es only a hin sideband
concen a ed a ound he dominan ha monic x = 84 Hz. The measu ed p o o ype o o s
con ain Nd = 20 ully closed slo s, and he pm had o be se highe han he es o o .
The equency band o se hus eaches Δ = 4.2 Hz.
Figu e 25. Ou pu s o a o o R1 (no de ec ).
In he g oup o o o s, a sample labeled R2 was ound ha showed a di e en o al
shape, see Figu e 26. FFT analysis indica ed he appea ance o a sideband in he lowe
equency ange. The o al pa e n is sepa a ed and he plo ing poin ci cula es along
mu ually il ed ellip ical shapes. F om his ou pu , we assumed ha his is a aul in he
end- ing.
Figu e 26. Ou pu s o a o o R2 (de ec in end- ing).
The assump ion was inally con i med by wo me hods, see Figu e 27. X- ay pho-
og aphy shows he p esence o ai bubbles ha almos comple ely ill he olume o he
Ene gies 2021,14, 6573 19 o 23
end- ing. The des uc i e me hod o cu ing h ough he end- ing illus a ed he scale o
his de ec , which signi ican ly educes he conduc i i y o he end- ing segmen s.
Ene gies 2021, 14, x FOR PEER REVIEW 20 o 24
Figu e 26. Ou pu s o a o o R2 (de ec in end- ing).
The assump ion was inally con i med by wo me hods, see Figu e 27. X- ay pho-
og aphy shows he p esence o ai bubbles ha almos comple ely ill he olume o he
end- ing. The des uc i e me hod o cu ing h ough he end- ing illus a ed he scale o
his de ec , which signi ican ly educes he conduc i i y o he end- ing segmen s.
Figu e 27. X- ay pho og aphy o es ed o o R2 and mechanical cu o end- ing.
The o o labeled R3 p esen s a sample wi h a combined aul in he o o ba s, see
Figu e 28. The in e nal c ossing o he ajec o y o he plo ing poin is cha ac e is ic o a
aul in he o o ba s.
Figu e 28. Ou pu s o a o o R3 (mul iple de ec ed o o ba s).
The FFT analysis indica es a signi ican p esence o sidebands on bo h sides o he
dominan ha monic and also a be e sensi i i y o he passi e senso o his ype o aul .
A cu made a 1/3 o he o o leng h exposed ai bubbles and deepe holes in se e al
o o ba s, see Figu e 29.
Figu e 29. Cu in 1/3 o he leng h o he sample R3.
Figu e 27. X- ay pho og aphy o es ed o o R2 and mechanical cu o end- ing.
The o o labeled R3 p esen s a sample wi h a combined aul in he o o ba s, see
Figu e 28. The in e nal c ossing o he ajec o y o he plo ing poin is cha ac e is ic o a
aul in he o o ba s.
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Figu e 26. Ou pu s o a o o R2 (de ec in end- ing).
The assump ion was inally con i med by wo me hods, see Figu e 27. X- ay pho-
og aphy shows he p esence o ai bubbles ha almos comple ely ill he olume o he
end- ing. The des uc i e me hod o cu ing h ough he end- ing illus a ed he scale o
his de ec , which signi ican ly educes he conduc i i y o he end- ing segmen s.
Figu e 27. X- ay pho og aphy o es ed o o R2 and mechanical cu o end- ing.
The o o labeled R3 p esen s a sample wi h a combined aul in he o o ba s, see
Figu e 28. The in e nal c ossing o he ajec o y o he plo ing poin is cha ac e is ic o a
aul in he o o ba s.
Figu e 28. Ou pu s o a o o R3 (mul iple de ec ed o o ba s).
The FFT analysis indica es a signi ican p esence o sidebands on bo h sides o he
dominan ha monic and also a be e sensi i i y o he passi e senso o his ype o aul .
A cu made a 1/3 o he o o leng h exposed ai bubbles and deepe holes in se e al
o o ba s, see Figu e 29.
Figu e 29. Cu in 1/3 o he leng h o he sample R3.
Figu e 28. Ou pu s o a o o R3 (mul iple de ec ed o o ba s).
The FFT analysis indica es a signi ican p esence o sidebands on bo h sides o he
dominan ha monic and also a be e sensi i i y o he passi e senso o his ype o aul .
A cu made a 1/3 o he o o leng h exposed ai bubbles and deepe holes in se e al o o
ba s, see Figu e 29.
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Figu e 26. Ou pu s o a o o R2 (de ec in end- ing).
The assump ion was inally con i med by wo me hods, see Figu e 27. X- ay pho-
og aphy shows he p esence o ai bubbles ha almos comple ely ill he olume o he
end- ing. The des uc i e me hod o cu ing h ough he end- ing illus a ed he scale o
his de ec , which signi ican ly educes he conduc i i y o he end- ing segmen s.
Figu e 27. X- ay pho og aphy o es ed o o R2 and mechanical cu o end- ing.
The o o labeled R3 p esen s a sample wi h a combined aul in he o o ba s, see
Figu e 28. The in e nal c ossing o he ajec o y o he plo ing poin is cha ac e is ic o a
aul in he o o ba s.
Figu e 28. Ou pu s o a o o R3 (mul iple de ec ed o o ba s).
The FFT analysis indica es a signi ican p esence o sidebands on bo h sides o he
dominan ha monic and also a be e sensi i i y o he passi e senso o his ype o aul .
A cu made a 1/3 o he o o leng h exposed ai bubbles and deepe holes in se e al
o o ba s, see Figu e 29.
Figu e 29. Cu in 1/3 o he leng h o he sample R3.
Figu e 29. Cu in 1/3 o he leng h o he sample R3.
Howe e , his does no au oma ically imply ha he p esence o ailu es in his c oss-
sec ion is comple e. Acco ding o he o al pa e n, he e a e p obably mo e damaged ba s,
o ba s wi h a high con en o ai bubbles o holes, in he es ed o o R3.
Ene gies 2021,14, 6573 20 o 23
7. Discussion
The p oposed sys em o aul de ec ion by using a g aphical pa e n is based on he
p inciple o ol age induc ion in a conduc o (ba ) mo ing in a s a ic magne ic ield. The
2-senso s measu emen s we e used o de e mine he quali y o he manu ac u ed o o .
The o e all summa y o he ad an ages and disad an ages o he me hodology used is
o ganized in he ollowing sec ions:
(A)
Senso design
The magne ic ield is gene a ed by pe manen magne s in he ac i e senso enclosu e.
The ad an age o his solu ion is he absence o exci a ion cu en , which is o he wise
necessa y when using a classical g owle yoke. To su icien ly magne ize he o o ee h,
a he s ong NdFeB magne s a e needed. The exci a ion canno be adjus ed, he e o e
he ai gap be ween he exci a ion yoke and he o o su ace mus be ela i ely small.
This makes he exci a ion sensi i e o s icking o e omagne ic pa icles and sawdus . In
labo a o y condi ions his is no a p oblem in p inciple, bu i he measu ing sys em is
implemen ed in a p oduc ion cycle, i mus be emembe ed ha sawdus can e en ually
c ea e a magne ic sho ci cui be ween he poles o he ac i e senso .
(B)
Tes sys em assembly
I is impo an o keep in mind he in luence o he su ounding en i onmen . The
e omagne ic mass enclosing he o o o be measu ed can cause high dis o ion in he
sensed signals. In ou case, he massi e clamping head showed o be he bigges p oblem.
The clamping sys em has o be made wi h non-magne ic ods ha a e a enough away
om he ac ual o o body.
(C)
Calib a ion o senso s using a es o o
The adjus men and alida ion o he me hodology used was e i ied on a es o o .
The design o he es o o should be as close as possible o he eal o o . This was no
ully me in ou case. The eal squi el cage o o does no con ain isola ed o o ba s
as in he case o he es o o . Du ing die cas ing, he o o slo s a e illed wi h mol en
aluminum and he o o ba comes in o di ec con ac wi h he o o pla es. The e is a
high p obabili y o in e ba cu en s, whe e he elec ic cu en lows pa ially h ough he
o o pla es and can bypass a mino de ec inside he ba . The c oss-sec ion o he ba in a
eal o o is no ci cula . The eal o o con ains a double cage, see Figu e 29. In addi ion,
he hickness o he end- ing o he eal o o is la ge, see Figu e 24. I he ai bubbles
occupy a signi ican pa o he end- ing c oss-sec ion, hen his de ec is qui e de ec able.
Howe e , i he po osi y o he ai bubbles is smalle , he p oposed measu emen sys em
shows lowe sensi i i y.
(D)
C i e ia o e alua ing pa e ns, sensi i i y
Fo a eal o o wi hou de ec s, he ajec o y o he plo ing poin in X-Y mode o ms a
egula and smoo h o al. The shape and dimensional p opo ions o his o al a e iden ical
o iden ical o o s wi hou de ec s. Such a o o hen plo s a ajec o y in X-Y mode which
is he e e ence o o he measu ed o o s o iden ical design. The ou e and inne bo de
o he o al is de ined by he ajec o y o he plo ing poin , which uns in a speci ic ange
a ound i s pe ime e . This p oduces he ypical wid h o he o al, he magni ude o which is
de e mined by he eccen ici y o a o o wi hou de ec s. The eccen ici y can be adjus ed
by using clamping conical ips inse ed in o he sha bo e and e i ied on he induced
ol age ime his o ies included in he es window.
Faul iden i ica ion is based on g aphical and isual compa ison o he plo ed pa e n
wi h a e e ence o al shape. The isual assessmen is (i) he inc ease in he wid h o he
o al om he e e ence pa e n, (ii) he sepa a ion o he ajec o y o he plo ing poin
om he e e ence wid h o he o al, (iii) he endency o he plo ing poin o o m in e nal
loops inside he o al, (i ) he numbe o in e nal loops o med.
Ene gies 2021,14, 6573 21 o 23
In he case o a mino de ec in he o o ba , he de o ma ion o he plo ing poin
ajec o y may no be comple ely e iden o an accu a e speci ica ion o he ype o ailu e.
By looking a he FFT analysis window, which is also pa o he es panel, he o o aul
can be speci ied mo e p ecisely. A double-sided sideband indica es a aul in he ba , a
le -sided sideband ep esen s a aul in he ing. Un o una ely, he sensi i i y o de ec s in
he end- ing is less o he ab ica ed es sys em han o de ec s in he ba s.
(E)
Measu emen ou pu s om es and eal o o s
As can be seen om Figu e 20b, a de ec in he od (ai bubble, educed conduc i i y)
is only de ec able a app oxima ely 25% loss in od c oss-sec ion. I was obse ed ha a
lowe aul anges <25% o od c oss-sec ion loss, he pa e n only sligh ly expands and
he aul esolu ion is wo se. The aul is much mo e iden i iable on FFT analysis o bo h
signals. In he case o a comple ely c acked ba o se o ba s, he pa e ns on Figu e 21b–d
show a signi ican de ia ion o he plo ing poin om he o iginal o al shape and hese
ypes o aul s a e e y well iden i iable. In he second phase o e i ica ion, he de ec s
in he end- ing we e measu ed. Again, i is e iden ha he ange o damage (po osi y)
had o achie e a leas 30% c oss sec ion loss o his de ec o be easonably isible, see
Figu e 22b.
Compa ing he ba and end- ing de ec , he di e ence in he ajec o y o he plo ing
poin is e iden . Wi h he ba aul , he hickness o he o al only sligh ly expands, and he
ajec o y o he plo ing poin o ms an in e nal c ossing. The o al g adually sepa a es in
he uppe le pa . In an end- ing aul , he indi idual o als a e sepa a ed and sligh ly
o a ed. The e ec o he segmen po osi y is e lec ed by he ajec o y de ia ion in he
lowe pa o he o al. The passi e senso is loca ed app oxima ely in he middle o
he o o leng h du ing he measu emen , and hus ac ually cap u es an image o he
ins an aneous alue o he cu en in he ba de e mined by he aul condi ion in he
end- ing segmen . The de ec abili y o a aul in he end- ing can be imp o ed i he passi e
senso is loca ed close o he end- ing and o ien ed pa allel o he axis o o a ion o he
o o being measu ed.
Fo a eal o o wi hou de ec s, he ajec o y o he ende ing poin in X-Y mode
o ms a egula and smoo h o al, see Figu e 25. The de ec in he eal o o can no longe be
explici ly se , as in he case o he es o o , bu he aul iden i ica ion is pe o med di ec ly.
As can be seen om Figu es 26 and 28, he de ec s in he eal o o a e mo e likely o occu
in a combined o m. The o al in Figu e 26 ends o inc ease in hickness and he e is only a
sligh c ossing o he plo ing poin ajec o y. The equency band is cen e ed o he le o
he dominan ha monic x = 84 Hz. The shape o he o al shows a cha ac e consis en wi h
an end- ing de ec . A se ies o c ossings and inne loops appea in Figu e 28. The loops in
he cen e o he o al a e smoo h and do no con ain sha p shapes. The ba s in he o o
will no be comple ely in e up ed, bu conside able po osi y can be expec ed. One o he
ods has a e y signi ican ly educed conduc i i y. The equency band appea s on ei he
side o he dominan ha monic x = 84 Hz.
8. Conclusions
The pape deal wi h o -line diagnos ics o he o o o an asynch onous machine
using wo senso s. The unc ionali y o he whole sys em o measu ing and iden i ying
aul s in he o o was i s ly e i ied using a 2D FEM elec omagne ic model. The FEM
analysis was also used o ind he app op ia e a angemen o he senso s and hei op imal
posi ion nea he o o . To alida e he measu emen sys em, a es o o was buil o
simula e he speci ic ypes o aul s and hei possible combina ions ha can occu in
squi el cage o o s. The e alua ion sys em includes a g aphical aul isualiza ion in e ace
ha displays ol age wa e o ms, FFT signal analysis, and o al pa e ns and is used o
iden i y speci ic o o aul s. I was impo an o ind cha ac e is ic pa e n shapes whose
shape co esponds o he simula ed aul . The g aphical ou pu s o he pa e ns se e as
addi ional in o ma ion o he ope a o o e alua e he quali y o he manu ac u ed o o . I
he plo poin de ia es signi ican ly om he e e ence shape o he egula o al, he o o

Ene gies 2021,14, 6573 22 o 23
can be conside ed as de ec i e and can be emo ed om he nex p oduc ion p ocess. The
inal decision can be made by he ope a o o by he au oma ed sys em.
Au ho Con ibu ions:
Concep ualiza ion, P.K. and P.B.; o mal analysis, P.B. and P.M.; in es iga ion,
P.B. and P.M.; me hodology, P.K. and P.B.; so wa e, P.K.; supe ision, P.K. and P.B.; alida ion, P.K.;
isualiza ion, P.K., P.B. and P.M.; w i ing—o iginal d a , P.K.; w i ing— e iew and edi ing, P.K. and
P.M. All au ho s ha e ead and ag eed o he published e sion o he manusc ip .
Funding:
This esea ch was unded by in e nal unding p og am SGS o he VSB—Technical Uni e -
si y o Os a a, iden i ica ion no: SP2021/20.
Ins i u ional Re iew Boa d S a emen : No applicable.
In o med Consen S a emen : No applicable.
Da a A ailabili y S a emen : No applicable.
Con lic s o In e es : The au ho s decla e no con lic o in e es .
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