International Journal of Computer and Electrical Engineering, Vol. 3, No.
2, April, 2011
1793-8163
A Novel Approach for Detection of Shorted
Turns Fault in Machine Using Combination of
Flux and Instantaneous Power Signal
Intesar Ahmed *a, Manzar Ahmed b, M. Shuja Khan**a and Kashif Imran a
Abstract—In this paper, non-invasive multiple sensors for
the detection of shorted turns fault have been used. The fault
has been detected using fault frequency components from flux
and instantaneous power and a single signal (combination of
flux and instantaneous power signals) called power-flux over a
wide range of loads. To achieve this task, stator winding of the
machine was re-wounded with taps to introduce shorted turns
fault. An extensive series of laboratory tests were conducted to
examine the fault frequency amplitudes for the healthy motor
and faulty motors with different shorted turns. Results based
on the variations in the amplitude of sideband components
between healthy and faulty motors versus different frequencies
over a wide range of loading conditions from different signals
have been analyzed experimentally in detail. Overall, this
paper provides comprehensive detail to detect the shorted turn
faults in machines using a novel combination of axial flux and
instantaneous power signals into a single signal called power-
flux.
Index Terms—Condition Monitoring, Non-invasive
techniques, Shorted turn fault, Power-Flux signal.
I. INTRODUCTION
It has been reported that 40% of machines failures are
due to shorted turn faults [1, 2]. It is well understood that
the impact of shorted turns in stator winding at early stages
on the induction machines is small. Shorted turn faults
result from insulation failure in a part of the winding. This
insulation failure can be caused by thermal damage due to
excessive currents, insulation breakdown as the result of
voltage spikes/transients and mechanical damage. Shorted
turn faults can produce either large fault currents which will
rapidly trip the circuit breaker or else produce little external
symptoms.
In the latter case, however, the localized heating caused
by the fault will gradually result in further insulation
damage until the motor fails. It is useful to be able to detect
such faults at an early stage so that a pre-planned shutdown
can be arranged for the motor to be replaced by a healthy
motor. Various causes of stator and rotor failures have been
presented and discussed in detail. A specific methodology is
proposed to facilitate an accurate analysis of these failures
[3]. An approach, based on the computer-aided monitoring
of the motor current Park’s Vector representation is
presented in [4]. Stator faults estimation
Manuscript received September 6, 2010.Department of Electrical
Engineering, a COMSATS Institute of Information Technology, Lahore,
Pakistan, b University of South Asia, Lahore, Pakistan,(Email:
*drintesarahmad@ciitlahore.edu.pk, **shuja@ciitlahore.edu.pk).
233
Figure 1: View of shorted turns in stator winding of faulty motor.
in induction machines have been detected by using Particle
Swarm Optimization and Residual Saturation Harmonics in
[5, 6]. Another method of detecting shorted turn stator fault
is based on a fuzzy model [7]. A combination of wavelet
and power-spectral-density techniques for the detection of
shorted turn faults in induction motors has been reported in
[8]. Although, condition monitoring is normally done for
induction motors [9], and it can also be carried out for
induction generators as well [10].
To overcome any shortcoming concerning the detection
of broken rotor bar fault in the machines using the fault
frequency components from the current, flux and
instantaneous power signals under different levels of
loading is presented in [11]. A comprehensive literature
review of more than 20 existing methods, including the
most common methods to assess the phase-to-ground,
phase-to-phase, and turn-to-turn insulation conditions is
presented in [12, 13]. Investigation of Multiple Faults
Detection in Electric Machine Using Broken Rotor Bar and
Eccentricity Fault Frequencies Techniques has also been
described in [14].
This paper explores non-invasive multiple-sensor types
for the detection of shorted turns fault using a novel
approach of combination of fault frequency components of
a single signal called power-flux over a wide range of loads.
To achieve this task, stator winding of the machine was re-
wounded with taps to introduce shorted turns fault as shown
in Fig. 1. An extensive series of laboratory tests were
conducted to examine fault frequency amplitudes for the
healthy and faulty motors with different shorted turns and at
different loading conditions ranging from 30 to 120 percent
load as given in Table 1.
TABLE 1: NUMBER OF TURNS SHORT-CIRCUITING TO INVESTIGATE THE
SEVERITY OF SHORTED TURNS FAULT VERSUS PERCENT OF RATED LOADS.
% of Rated Number of shorted turns
Load 0 5 10 15 20
30 9 9 9 9 9
 International Journal of Computer and Electrical Engineering, Vol. 3, No. 2, April, 2011
1793-8163

50 9 9 9 9 9 TABLE 2 :TECHNICAL INFORMATION FOR THE INDUCTION MOTOR

75 9 9 9 9 9 USED IN THE TESTING.
100 9 9 9 9 9 Performance Data Value
120 9 9 9 9 9 Rated voltage (V) 415
Rated frequency (Hz) 50
II. EXPERIMENTAL SETUP
Rated current (A) 4.8
The experimental work was conducted using the test rig
Power (kW) 2.2
and data acquisition system as shown in Fig. 2. The tests
were conducted on a set of healthy and faulty three-phase Number of Poles 4
induction motors (T-DF100LA, manufactured by Brook Rated speed (rpm) 1415
Crompton), which were loaded by a dynamometer Rated torque (Nm) 14.8
consisting of a 5 kW separately excited DC machine, using Number of rotor slots 32
a variable-resistance bank. The detailed technical
Power factor at full-load 0.81
specifications of the induction motors under test are shown
in Table 2. The induction motor under test was
TABLE 3 :TECHNICAL INFORMATION ABOUT THE DC MACHINE
mechanically coupled to a separately excited DC machine, USED IN THE TESTING.
which was loaded using a variable-resistance bank.
The wiring diagram of the AC and DC systems is shown Performance Data Value
in Fig. 3. The specifications of the DC machine used as a Rated shaft power (kW) 5.5
load in the testing are shown in Table 3. During the tests, Rated speed (rpm) 1500
the two current sensors for line currents, two voltage Rated armature voltage (V) 220
sensors for line voltages, one axial leakage flux sensor, two Rated armature current (A) 28
vibration sensors: drive-end horizontal (DEH) and drive-end Rated field current (A) 0.65
vertical (DEV), and one speed sensor directly connected to There are number of factors which can affect the
the shaft of motor, were used. accuracy of the measurements. Some of these factors are the
The position of the sensors in the test arrangement is rigidity of the foundation of the test motor and the accuracy
shown in Fig. 3. The axial leakage flux measurement was of the shaft alignment. The motors must have a firm and
taken with a circular search coil of comparable diameter to rigid foundation to eliminate soft foot problems and to
the motor, which is mounted concentrically with the shaft reduce vibration [10].
on the rear of motor. For reliability and consistency of the During the measurements the sensors were sampled
flux measurements, a fixed position for the flux coil is simultaneously and two different sampling rates used in this
defined. study are as follows:
The vibration sensors were screw-mounted to the motor
housing to achieve the highest measurement bandwidth. • Low-frequency measurement with a 400 Hz sampling
Measurements of the input stator currents and voltages were frequency that gives a Nyquist frequency of 200 Hz,
taken using a custom-built measurement box that was and 100 second sampling time, which allow very high-
located between the auto-transformer and the test motor. resolution frequency analysis (40,000 data points, 0.01
The speed sensor was directly attached to the motor shaft to Hz resolution).
obtain the running speed of motor as shown in Fig. 3. VA VB VC
The analog signals from the sensors are passed through
M ains supply

low-pass filters to remove any high frequency components Current Sensor

D ata acquisition system

Voltage Sensor
that may cause aliasing. This is performed by an 8 channel,
L ow -pass filter
S ignal processing

8th order Butterworth analog low-pass filter unit with PC

selectable cut-off frequencies of 100 Hz for the 400 Hz
sampling frequency and 2 kHz for the 8 kHz sampling
frequency. Table 4 illustrates the specifications of the
sensors used for measurements in this study.
DEV Vibration
Sensor
A xial F lux
S ensor

DEH Vibration Speed

Sensor 5 kW DC generator
Sensor
Induction Motor

Figure 3: The block diagram of the test set-up including the positions of the
sensors [9].

[1] High-frequency measurement at 8000 Hz sampling

frequency with a sampling time of 5 seconds (40,000
Figure 2: Data-acquisition hardware (left) and motor/load test set-up (right).
data points, 0.2 Hz resolution).

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1793-8163

The parameters of the two sampling rates, achieved

frequency resolution, frequency range, setting of anti- Faulty motor (n=1 and k= -1) at 30%
aliasing filter and usable frequency ranges of each sampling load
rate used for experiments are given in [15].

III. SHORTED TURNS FAULT DETECTION USING FLUX

SPECTRUM
Measured fault frequencies and their respective
magnitudes for the healthy and faulty motor (20 shorted
turns) for n=1 and k= ±1, ±3, ±5 at 30% is shown in Fig. 4
and Fig. 5 respectively.
The spectra showed significant decrease for both negative
and positive sideband in the amplitudes of fault frequency Faulty motor (n=1 and k=1) at
components regarding the healthy and faulty motors. The 30% load
amplitudes of the sidebands are clearly visible in the flux
spectrum for different values of n and k, even in the
presence of other peaks and high noise level when
compared to the current spectrum. The noise level is about –
65 dB.
The results show that it is useful to detect the shorted turn
faults at light loads using the flux signal. However, the
features of flux signal cannot provide useful information to
detect the shorted turn faults at high loads. Since the flux Figure 5: Under 30%-load test conditions, variations in the amplitudes of
signal showed could detect shorted turn faults at light loads the healthy and faulty motors were found to be less than 4 dB for all values
therefore, the next section will examine the variability in of k except for k=1, which is clearly visible in the spectra.
healthy motors. This is made possible by test repeatability, 0
difference between identical motors, and difference between Flux Spectrum : f1[(n/p)(1-s)+/-k)]
the phases of the same motors tests. This will confirm the -20 Healthy
accuracy and reliability of the test results in finding shorted noise level = - 65 dB
Faulty(20 ST)
Amplitude (dB)

at 30% load
turn faults using shorted turn fault frequencies components. -40

Healthy motor (n=1 and k= -1) at -60

30% load
-80

-100
-5 -3 -1 1 3 5
(K)

0
Flux Spectrum : f1[(n/p)(1-s)+/-k)]

-20 Healthy
Faulty(20 ST)
noise level = - 65dB
Amplitude (dB)

at full-load
-40

Healthy motor (n=1 and k=+1) at

-60
30% load

-80

-100
-5 -3 -1 1 3 5
(K)
Figure 6: Comparison of variation in shorted turn sideband amplitude
versus percent of rated load of healthy motor at 30% load and at full-load.

A. Flux Spectrum Variations for Healthy Machines

Figure 4: Highlights variations in the amplitudes of sideband components
for n=1 and k= ±1 is more than 14 dB for both the negative and positive To examine the accuracy and reliability of the test results
sideband components at 30% load. to detect shorted turn faults using fault frequency
components from flux signal, a set of three tests on the same

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1793-8163

healthy motor was conducted. Each test was repeated after 0

Flux Spectrum : f1[(n/p)(1-s)+/-k)]
the motor had been removed from the test rig and returned.
Fig. 7 below summarizes the test results of three -20
consecutive tests on the same healthy motor at 30% load for

Amplitude (dB)
the different values of k. The results show the maximum -40
variations in the sideband amplitudes for the healthy motor
is less than 4 dB at 30% load, which is not significant and -60
does not affect the accuracy and reliability of the test results phase A phase B
faulty A faulty B
obtained by using the shorted turn fault frequency Load = 30%
-80
components. The faulty motor result is shown for reference. noise level = -90 dB
Fig. 8 shows a comparison of the variations in the
amplitudes of the shorted turn sideband components -100
-5 -3 -1 1 3 5
versus % of rated load for two similar rating (2.2 kW) of K
motors and the variations for any value of k is less than 4
dB, which are not significant. The finding demonstrates the Figure 9: Variations in shorted turn sideband amplitudes for tests on two
reliability of test results. Fig. 9 shows variations in the nominal identical healthy motors. Faulty motor result is shown for
sideband amplitudes between phases A and B for a healthy reference.

motor and faulty motor with 20 shorted turns for different

values of k at 30% load.
The variations in the amplitudes of fault frequency IV. SHORTED TURNS FAULT DETECTION USING
components for the two phases of the healthy and faulty INSTANTANEOUS POWER SPECTRUM
motors showed slight variations of less than 3 dB for any The Frequency spectra of the power signal for a healthy
value of k. In summary all three tests showed that the test and a faulty motor for n=1 and k=±1 at full-load are shown
results are accurate and reliable. in Fig. 10, which are used to detect shorted turn faults in the
machines. The spectrum showed the significant variations
0 emerged in the amplitude of fault frequency sideband
Flux Spectrum : f1[(n/p)(1-s)+/-k)] components in the faulty motor and are clearly visible in
-20
comparison to the healthy motor.
The results shown in Fig.10 are much clearer separated in
the amplitude of sideband component at 100% load for n=1
Amplitude (dB)

-40
and k=±1. It can be concluded that the instantaneous power
signal showed slightly more variations in the amplitude of
-60 noise level = -65 dB negative sideband components at 100% load when
compared to the result for the flux spectra.
test 1 test 2
-80 test 3 faulty However, results obtained at 30 % load showed slight
Load = 30%
variations in the amplitudes of fault frequency components
-100 for the healthy and faulty motor. Therefore, on the basis of
-5 -3 -1 1 3 5 these results, instantaneous power is useful for detecting
K
shorted turn faults at 100% load.
Figure 7: Comparison of variations in flux sideband amplitudes for three Since the instantaneous power signal can detect shorted
tests on the same healthy motor.
turn faults at higher loads, it is important to examine the
0 variability of the instantaneous power signal in order to
Flux Spectrum : f1[(n/p)(1-s)+/-k)] confirm the reliability of the test results to detect shorted
-20
turn fault using instantaneous power signal.
A. Instantaneous Power Variations For Healthy
Amplitude (dB)

-40 Machines
Fig.12, 13 and 14 depict the healthy motor results
-60 noise level = -65dB regarding: repeatability tests on the same motor; differences
between motors; and differences between the motor’s
motor1 motor 2
-80 faulty phases for confirming the reliability of the test results in
Load = 30%
detecting shorted turn faults from the instantaneous power
signal.
-100
-5 -3 -1 1 3 5 Fig.12 summarizes the variation in the sideband
K amplitudes versus different values of k at 100% load and a
set of three tests. The variation was found to be less than 3
Figure 8: Variations in shorted turn sideband amplitudes for tests on two dB, which is very small.
nominal identical healthy motors. The result of faulty motor is shown for
reference. Fig. 13 compares the instantaneous power sideband
amplitudes versus different values of k at 100% load for the
two nominally identical healthy motors and demonstrated a
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1793-8163

small variation of 4 dB, which is not significant. 0

Instt. power Spectrum : fp[(n/p)(1-s)+/-k)]
Fig. 14 highlights the variation in the sideband
amplitudes between phases A and B for a healthy and faulty -20 Healthy

motor. The variation in the amplitudes for both phases is Faulty(20 ST)

Amplitude (dB)
at 30% load
less than 3 dB, which is also very small. -40
It can be concluded from the three different tests on the noise level = - 95 dB

healthy motor that no significant variations were found in -60

the amplitudes of fault frequency components, and this
confirms the accuracy and reliability of the test results. -80

-100
-5 -3 -1 1 3 5
Healthy motor (n=1 and k=-1)
(K)
at full-load

Healthy motor (n=1 and k=+1)

at full-load

Figure 11: Variations in the shorted turn sidebands amplitudes versus % of

rated load of healthy motor for different values of k from instantaneous
power spectrum.
0
Intt.Power Spectrum : fp[(n/p)(1-s)+/-k)]

-20
test 1 test 2
faulty test 3
Amplitude (dB)

-40 Load = 100%

Faulty motor (n=1 and k=-1) at -60

full- load
-80
noise level = -95 dB

-100
-5 -3 -1 1 3 5
K
Figure 12: Variations in shorted turn sideband amplitudes for three tests on
the same healthy motor at full-load.

0
Instt.Power Spectrum : fp[(n/p)(1-s)+/-k)]

-20

motor 1
Amplitude (dB)

motor 2
-40 faulty
Faulty motor (n=1 and k=+1) Load = 30%

at full-load -60

-80
noise level = -95 dB

-100
-5 -3 -1 1 3 5
K
Figure 10: indicates variations in the amplitudes of the healthy and faulty Figure 13: Variations in the shorted turn sideband amplitudes for tests on
motor with 20 shorted turns at 100% load tests for n=1 and k=±1. two identical healthy motors at 100% load.

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1793-8163

0
0
Instt. Power Spectrum : fp[(n/p)(1-s)+/-k)]
Instt.Pow er : f p[(n/p)(1-s)+/-k)]
-20 -20
k=1

Amplitude (dB)
healthy motor
Amplitude (dB)

phase A phase B
-40 faulty B faulty A
-40 faulty motor
Load = 30% -57.83 dB
-60 -60 -59.66 dB

-80 -80
noise level = -95 dB
-100
-100
-5 -3 -1 1 3 5 0 30 60 90 120
K % Rated Load
Figure 14: Variations in shorted turn sideband amplitudes of the healthy
motor between phases A and B at full-load. 0
Com bined Single Signal

V. COMBINATION OF FLUX AND INSTANTANEOUS -40 k=1

Amplitude (dB)
POWER SPECTRA healthy motor
-83.87dB faulty motor
-80
Fig. 15 shows the measured shorted turn sideband
-99.6 dB
amplitudes for healthy and faulty motor (20 shorted turns)
over a wide range of loads from the flux, instantaneous -120
power and single power-flux signal.
The results obtained from the flux signal indicate that
shorted turn causes sideband amplitudes to decrease as the -160
load on the motor increases. However, flux signal proved 0 30 60 90 120
more suitable and in fact preferable for detecting shorted % Rated Load
turn faults at light loads, while the instantaneous power is Figure 15: Variations in the sideband amplitudes for the healthy and faulty
able to detect shorted turn faults at heavy loads. Therefore, motor (with 20 shorted turns). Top row (left) and top row (right) show the
it is difficult to set a threshold between the healthy and flux and instantaneous power. The Bottom (row) represents a single signal.
faulty motors.
To overcome this difficulty, a novel approach has been In summary, the single signal is preferable for detecting
used as a combination of both flux and instantaneous power shorted turn faults over a wide range of loads for the
signals into a single signal called “Power-Flux Signal”. Flux different values of k when compared to the results obtained
signal and instantaneous power signal are used in a from flux and instantaneous power signals separately.
combination of Power-Flux signal. The best feature of the
Power-Flux signal is that the sideband amplitudes between
the shorted turn fault frequency components are generally VI. CONCLUSION
higher as shown in Fig. 15 (bottom row). It is thus easier to Non-invasive multiple sensors for the detection of
set a threshold between the healthy and faulty motors to shorted turns fault using fault frequency components from
determine the shorted turn fault severity using combined flux signal, instantaneous power signal and a single signal
power-flux signal. (combination of flux and instantaneous power signals)
called power-flux over a wide range of loads has been
0 presented in this paper. Using fault frequency components
Flux Spectrum : f1[(n/p)(1-s)+/-k)] to detect the faults and estimate fault severity in the
-20 machines relies heavily on variations in the amplitudes of
-26 dB sideband components. The results for the flux signal
Amplitude (dB)

-40 -40 dB showed that it is not able to provide useful information to

detect shorted turn faults at higher load and is only useful
-60 for finding shorted turn faults at light loads but only for the
k=1 specific values of k i.e. -5 to +5. Instantaneous power signal
healthy motor exhibited that there is enough separation between the
-80 faulty motor
healthy and faulty motors in the frequency spectra at full-
-100
load for the different values of k. In contrast, results
0 30 60 90 120
obtained at 30 % load showed small variations in the
amplitudes of fault frequency components. Therefore, on
% Rated Load
the basis of the results obtained, instantaneous power is
useful for detecting shorted turn faults only at heavy loads.
The use of single power-flux signal demonstrated that it can
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 International Journal of Computer and Electrical Engineering, Vol. 3, No. 2, April, 2011
1793-8163
be used to detect shorted turns fault and showed much
clearer variations between healthy and faulty motors over a
whole range of loads (from no-load to full-load).
ACKNOWLEDGEMENTS
The authors would like to acknowledge their respective
universities for providing adequate resources and
environment for research.
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Intesar Ahmed received Phd Electrical Power
Engineering from University of Adelaide, South
Australia and M.Sc. in Electrical Power
Engineering from University of New South Wales,
Sydney, Australia in 2007 and 1994 respectively.
Dr. Intesar has been involving in various
research projects relating to online condition
monitoring of electrical machines, power
electronics, and study of multiple faults in electric
machines via signal processing techniques.
Manzar Ahmed received MS in
Telecommunication from Asian Institute of
Technology, Thailand and B.Sc. in Electrical
Engineering from University of Engineering &
Technology, Lahore Pakistan in 2001 and 1991
respectively.
His current research interests include electric
machines and drives, electromagnetic
computational and electromechanical actuation as
well as techniques for energy savings.
Muhammad Shuja Khan received MS degree in
Electronic Engineering from Ghulam Ishaq Khan
Institute (G.I.K.I.) of Engineering. Science &
Technology, Swabi Pakistan and B.Sc. Electrical
(POWER) Engineering from University of
Engineering & Technology, Lahore Pakistan in
June 2009 and July 2007 respectively.
He joined COMSATS Institute, Lahore
Pakistan on August 2009 as Lecturer in
Department of Electrical Engineering.
He has successfully conducted and taught one Short Certificate Training
Course of “Power Distribution System Design” in Spring 2010. His
interests include MEMS Design and Multiple faults in Machines.
Engr. Shuja was awarded Higher Education Commission Pakistan
Indigenous Fellowship Award for hid MS program at G.I.K.I. 2007-09. He
was also awarded two International Travel Grants for presenting his
research paper in ICSCT 2009 and ICMENS 2010 held in South Korea
and China respectively by HEC Pakistan.
Kashif Imran received his elementary education
from England where he obtained GCSEs and
GCEs.He did B.Sc. and M.Sc. in Electrical
Engineering from University of Engineering and
Technology (UET), Lahore, Pakistan. His area of
specialization during both degrees was Electrical
Power. He started his career as a Lecturer at UET
Lahore. Then he moved to SIEMENS where he
worked as Engineer on project coordination of
132kV grid stations.
Later he joined NESPAK, leading engineering consultancy firm of
Pakistan, as a Design Engineer in Power Distribution Section. In NESPAK,
his professional experience includes design of overhead and underground
power distribution systems for a variety of buildings and installations.
Currently, he is Lecturer at COMSATS Institute of IT, Lahore, Pakistan
where he teaches Electric Machines. His book titled “Power Exchange as a
Deregulated Electricity Market” has been published by LAP Lambert
Academic Publishing, Germany. His research interests include Power
System Economics, Restructured Power Systems Simulation, Energy
Management Systems and Online Condition Monitoring of Electric
Machines.