Fault Detection of 3-Phase Induction Motor

Using Vibration monitoring

( Guided by :Naveen Kumar (B14EE021)
2nd year Electrical Engineering
B-Tech Project
IIT Jodhpur

Abstract
Induction motors are used worldwide in
industrial applications. These devices are highly
reliable. These devices are susceptible to many
type of faults. Fault detection of 3-phase
induction motors are of great importance in
production line. It can reduce the cost of
maintenance and the risk of unexpected failure.
In this project we have used vibration sensor to
detect the faults. In this paper we have detected
bearing faults. The fault discuss in this paper is
bearing faults.

Dr. Abdul Gafoor Shaik )

Ramesh Kumar (B14EE025)
2nd year Electrical Engineering
B-Tech Project
IIT Jodhpur

complete failure of induction

unexpected production costs.

motor

and

The main reason for the motor faults is

mechanical and electrical stresses. Mechanical
stresses are caused by overloads and abrupt
load changes, which may cause bearing faults
and rotor bar breakage. The electrical stresses
may produce stator winding short circuits and
result in a complete induction failure. There are
different type of fault in induction motor some of
them as follows

Keywords
Induction Motor, piezoelectric accelerometer, NI
Module, Balanced supply, Faulty bearings

Introduction
Fault detection and protection of induction motor
are very important. Induction motors are critical
component in many industrial processes. They
are very robust and highly reliable machines.
There are many type of fault in induction motor.
Failure of such motors may cause plant
shutdown, personal injuries, waste of raw
material. However, Induction motor faults can be
detect in initial stage in order to prevent

Bearing Faults
Bearings are common elements of electrical
machine. They are employed to permit rotary
motion of the shafts. Bearings are single largest
cause of machine failures. According to some
statistical data, bearing fault account for over
40% of all motor failures. Bearing consists of two
rings called the inner and the outer rings. A set

of balls or rolling elements placed in raceways

rotate inside these rings. A continued stress on
the bearings causes fatigue failures, usually at
the inner or outer races of the bearings. Small
pieces break loose from the bearing, called
flaking or spalling. These failures result in rough
running of the bearings that generates
detectable vibrations and increased noise levels.
This process is helped by other external
sources, including contamination, corrosion,
improper lubrication, improper installation, and
brinelling. The shaft voltages and currents are
also sources for bearing failures. These shaft
voltages and currents result from flux
disturbances such as rotor eccentricities. High
bearing temperature is another reason for
bearing failure. Bearing temperature should not
exceed certain levels at rated condition.
Bearing faults can be diagnosed with help
of many condition monitoring methods such as
vibration monitoring, temperature monitoring,
chemical
monitoring,
acoustic
emission
monitoring, current monitoring, etc. Except for
current monitoring, all these monitoring methods
require expensive sensors or specialized tools
and are usually intrusive.
So basically there are three type of
bearing faults in three phase induction motor as
follows:
Ball Defect

Outer Raceway defect

Inner Raceway Defect

A.

Ball Defect :balls are used in bearings to

provide relative motion between
inner and outer cages. These
balls are subjected to many
type of faults. When there are
less number of balls or not

enough lubricant, then ball

defect can be there. If balls are
rough or more friction is there
between the rings and balls,
then
also
bearing
may

experience faults.

B.

Inner Raceway Defect :we know that there are two

rings in a bearing. When a fault
occurs in inner ring it is called
as inner raceway defect. fault
can be some hole on the
surface of rings, some cracks
on the rings or damage of inner
ring.

C.

Outer Raceway Defect

:when a fault occurs in outer ring
it is called as outer raceway
defect. fault in outer ring is very
similar to inner ring. Faults can
be generated by drilling a hole,
some damage etc.

Experiment Set up
In this study we used vibration monitoring to
detect vibration signals. In this whole experiment
we used three phase induction motor, NI data
acquisition
card
9203,
a
piezoelectric
accelerometer, personal computer with MATLAB
2013 and lab VIEW software 2010 and
connecting wires. The bearings of the induction
motor are single row, deep groove ball bearing
and type 6024. The experiment was conducted
on three bearings. These bearings are subjected
to different type of bearing faults which were
discussed earlier. For detecting the faults, a test
bench is made as shown in the figure. Here
bearings are single raw, deep groove ball
bearing and type 6024. Each bearing has eight
balls.

Experiment set up test bench

condition monitoring simply means that

to access the condition of motor. There are
different type of condition monitoring for
detecting the faults, out of which We have used
vibration monitoring to detect the faults.
Basically we have a piezoelectric sensor
(accelerometer) which works as a vibration
sensor. It is sensing the vibrations. It has one
plane surface and one output terminal. Plain
surface is connected to vibrating surface and

output can be taken by its output terminal.

Simply mean it is converting mechanical signals
into electrical signals. We have taken data for
different positions of induction motor. For storing
the accelerometers output a NI Module is used.
It is storing the data which vibration sensor is
producing. After this data is processed by Lab
VIEW software. Using this software vibration
amplitude verses time graph is generated.
Program me for taking data from NI Module is
shown below. Then we saved this graph and
using MATLAB we have plotted FFT graph of
this amplitude time graph.
Processing diagram

Procedure

Frist of all we have taken readings for healthy

(normal) motor, which has no faults. We have
taken all data under no load condition. We have
taken readings on different points of horizontal
axis and vertical axis. Data for normal motor is
stored. Then we have changed its bearing. Now
we observe that there are noise and vibrations.
For this fault we have taken readings for same
point of horizontal and vertical axis. Similarly, we
have taken data for all three type of faults. By

seeing their FFT graph we can easily say about

what type of fault is this.

LabVIEW programme

Result and observations

Recorded data for healthy motor as

follows

Horizontal point 1

FFT of horizontal point 1

Horizontal point 2

FFT of horizontal point 2

Vertical point 1
FFT of vertical point 1

Vertical
point 2
FFT of vertical point 2

These data are recorded under ball defect

Horizontal point 1

FFT of horizontal point 1

Horizontal point 2
FFT of horizontal point 2

Vertical
point 1
FFT of
vertical
point 1

Vertical point 2
FFT of vertical point 2

For inner raceway defect recorded data are as follows

Horizontal point 1
FFT of horizontal point 1

Horizontal point 2

FFT of horizontal point 2

Vertical point 1
FFT of vertical point 1

Vertical point 2

FFT of vertical point 2

These data are recorded under outer raceway defect.

Horizontal point 1

FFT of horizontal point 1

Horizontal point 2
FFT
of

horizontal point 2

Vertical point 1
FFT of vertical point 1

Vertical point 2
FFT of vertical point 2

Conclusion and Future

work
The aim of this project is to detect the faults
using vibration monitoring. In this study, we have
designed fault detection circuit and implemented
successfully. If any bearing fault occurs in three
phase induction motor, we can easily detect that
fault by seeing their amplitude-frequency graph
So far we have detected the faults. Now we
can design a circuit for preventing the complete
motor failure. If any fault occurs in induction
motor, then using protection circuit we can stop
the motor and can get the knowledge about
faults.

Acknowledgement

References
We express our sincere thanks to our mentor,
Dr. Abdul Gafoor Shaik (assistant professor of
electrical engineering at IIT Jodhpur) for his
expert guidance, supportive, being helpful. We
also thanks to our TA Megha Singh and
Bhuvnesh Rathore for helping us to complete
our project.

Sumit Narwade, Prasad Kulkarni, C.Y.

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