Condition Monitoring and Fault Diagnosis of Induction Motors

Condition Monitoring and Fault Diagnosis of Induction Motors using Vibration Signal

Bo-Suk Yang*, Tien Han, Won-Woo Hwang and Kwang-Jin Kim

Intelligent Mechanics Laboratory School of Mechanical Engineering Pukyong National University

Condition Monitoring and Fault Diagnosis of Induction Motors

Applications

Induction Motors

Condition Monitoring and Fault Diagnosis of Induction Motors

Why the condition monitoring/diagnosis is important?

Degradation of different parts Although the motor cost, repair and refurbishment expense might not be substantial but the cost associated with down time is enormous Condition monitoring provides
Adequate warning of imminent failures Diagnosing present maintenance needs Schedule future preventive maintenance and repair work Minimum downtime and optimum maintenance schedules

Fault diagnosis
Allows the machine operator to have the necessary spare parts before the machine is stripped down, thereby reducing outage times Can be integrated into the maintenance policy, therefore the usual maintenance at specified intervals can be replaced by a condition-based maintenance

Condition Monitoring and Fault Diagnosis of Induction Motors

Typical faults of Induction motors

Failure survey in induction motors Components Bearing Stator Rotor Others Failure 40% 38% 10% 12%

Ref. IEEE Motor Reliability Working Group

Condition Monitoring and Fault Diagnosis of Induction Motors

Comparison of detection technologies

Faults it can detect Air-gap eccentricity Rotor bar broken Insulation Stator winding Bearing damage

Method

Vibration MCSA Axial flux Lubricating oil debris Cooling gaps Partial discharge

No No No No Yes Yes

No Yes Yes No Yes No

Yes Yes Yes No Yes No

Yes Yes Yes No No No

Yes Yes No Yes No No

Condition Monitoring and Fault Diagnosis of Induction Motors

Why we choice the vibration method?

Very popular, easy and accurate Favored by mechanical engineers Exists a lot of skilled and experience Often a direct link with the problem Piezo-electric vibration transducers are most popular Axial, radial, and tangential where radial is used for mechanical problems and tangential is used for detecting electrical problems

Condition Monitoring and Fault Diagnosis of Induction Motors

What kind of system we use?

Vibration Signature

Data acquisition

Machinery (Motor)

Pre-processing
Wavelet transform

Feature extraction
Feature algorithm

Fault diagnosis
ART-KNN

Scheme diagram of condition monitoring and diagnostics system

Condition Monitoring and Fault Diagnosis of Induction Motors

What would this system do?

Alert the user of an impending mechanical or electrical faults Provide early detection of machinery deterioration Prevent costly damage failure and/or unsafe operation

Condition Monitoring and Fault Diagnosis of Induction Motors

Motor cross section

Condition Monitoring and Fault Diagnosis of Induction Motors

Experimental apparatus design

Full load

Over load

Bearing

Pitch variable (8) blades

Motor

Common bed

Condition Monitoring and Fault Diagnosis of Induction Motors

Sensors positions
Control Panel

(Channel 5-8) Accelerometers

Speedometer (Channel 4) (Channel 4) Channel 1-3: current signal Channel 4: run speed Channel 5-8: vibration signal AC current probes (Channel 1-3)

Condition Monitoring and Fault Diagnosis of Induction Motors

Measuring instruments
B & K Condition Amplifier

4-channel Sony recorder (Model: PCEO4AX)

8-channel Mobile FFT Analyzer (ZONIC Model: 2300)

Condition Monitoring and Fault Diagnosis of Induction Motors

Mechanical problems
Fault Unbalance Misalignment & bent shaft Damaged rolling element bearing (ball, races, etc.) Damaged and worn gears Mechanical looseness Rotor rub Dominant Vibration Frequency 1x rpm ( temperature & lad dependent) 1x rpm usually, 2x rpm often, 3x & 4x rpm sometimes Impact rates for the individual bearing components. Also vibrations at very high frequencies. Tooth meshing frequencies (shaft rpm teeth number) and harmonics 2x rpm 0.5x, 1.5x, 2.5x, 3.5x, etc. 0.5x, 1x, 1.5x, 2x, etc.

Oil whirl & whip in sleeve bearings 0.43-0.48x rpm pressure fed bearings only

Condition Monitoring and Fault Diagnosis of Induction Motors

Electrical problems
Fault Unbalanced supply inputs Stator asymmetry (unbalanced supply, inter turn short) Rotor asymmetry (broken rotor bar, broken end ring) Eccentricity (static/dynamic) Adjustable speed drives Dominant Vibration Frequency 1x supply frequency Double supply frequency Double slip frequency 1x-slip frequency Double supply Double slip frequency 6x supply and harmonics

Condition Monitoring and Fault Diagnosis of Induction Motors

1. Bearing fault causes

Improper lubrication Contamination Corrosion Improper installation/misalignment

Condition Monitoring and Fault Diagnosis of Induction Motors

Fault frequency of bearing elements

Condition Monitoring and Fault Diagnosis of Induction Motors

Bearing fault (outer race)

Mfg. Brg. No. Ball No. R.E Dia. Pitch Dia. FTF BPFO BPFI BSF

NSK

6203

0.3125

1.319
3X 178.59 Hz 172.95 Hz

0.3835

3.066

4.932

2.03

Condition No-load Full-load

0.10 0.08 0.06 0.04

Running speed 59.53 Hz 57.65 Hz

Normal condition Bearing fault

Theoretical value 182.5190 Hz 176.7549 Hz

0.10 0.08 0.06 0.04

Test value 181.4067 Hz 174.375 Hz

Normal condition Bearing fault

Amplitude

0.02 0.00 -0.02 -0.04 -0.06 -0.08 -0.10 0.00 0.01 0.02 0.03 0.04 0.05 0.06

Amplitude

0.02 0.00 -0.02 -0.04 -0.06 -0.08 -0.10 0.00 0.01 0.02 0.03 0.04 0.05 0.06

Time (s)

Time (s)

No-load condition

Full-load condition

Condition Monitoring and Fault Diagnosis of Induction Motors

Characteristic frequency components: 1x, 2x, 3x and fo

0.020 horizental axial vertical (output) vertical (rear)

0.020 horizental axial vertical (output) vertical (rear)

fo

0.015 Amplitude

0.015

0.010

Amplitude

0.010

1x
0.005

0.005

2x 1x

3x

2x

3x

fo
0.000

0.000 0 20 40 60 80 100 120 140 160 180 200 Frequency (Hz)

20

40

60

80 100 120 140 160 180 200 Frequency (Hz)

No-load condition

Full-load condition

Condition Monitoring and Fault Diagnosis of Induction Motors

Wavelet transform

No-load condition

Full-load condition

Condition Monitoring and Fault Diagnosis of Induction Motors

2. Rotor bar damage

Rotor bar damage Damage condition Depth : 15.0 mm Diameter: 5.0 mm

Total rotor bar : 34 Broken bar : 12

Condition Monitoring and Fault Diagnosis of Induction Motors

Main reasons for the rotor bar and end ring breakage are: Thermal stress due to thermal overload and unbalance, hot-spots, sparking or excessive losses Magnetic stress caused by electromagnetic forces, unbalance magnetic pull electromagnetic noise and vibration Residual stresses due to manufacturing problems Dynamic stresses arising from shaft torque, centrifugal forces and cyclic stress Environment stresses caused by contamination or abrasion of the rotor materials due to chemical or moisture Mechanical stress due to loose laminations, fatigued parts or bearing failure

Condition Monitoring and Fault Diagnosis of Induction Motors

Detection of broken rotor bar

Frequency components in axial vibration signal due to axial force f = {(- qa + qb) + (qa - qb) s} fs , f = {(2 - qa - qb) + (qa + qb) s} fs
Where fs is the supply frequency in hertz, s is the slip, qa, qb = 1, 2, 3

Condition Monitoring and Fault Diagnosis of Induction Motors

Characteristic frequency components: sf sideband on the supply frequency

Motor axial direction
0.0010

0.0010

0.0008

0.0008

Amplitude

3 f 3sf
0.0006

Amplitude

0.0006

0.0004

3 f 10 sf 2x 1x 2f - sf 2f + sf

0.0004

1x f + sf 2x

3x

0.0002

0.0002

0.0000 0 20 40 60 80 100 120 140 160 180 200

0.0000 0 20 40 60 80 100 120 140 160 180 200

Frequency (Hz)

Frequency (Hz)

No-load condition

Full-load condition

Condition Monitoring and Fault Diagnosis of Induction Motors

3. Rotor unbalance
Experimental objective Mechanical unbalance effect to vibration signal Experimental conditions Adding unbalance mass at an end of end ring Unbalance condition
Mass : 8.4 g Distance: 40.2 mm Position: 0 , 36 , 72
Unbalance mass

Condition Monitoring and Fault Diagnosis of Induction Motors

Characteristic frequency components: 1x

0.0020 0.0018 0.0016 0.0014

Noraml Unbalance

0.0020 0.0018

Unbalance Noraml

1x

1x
Amplitude

0.0016 0.0014 0.0012 0.0010 0.0008 0.0006 0.0004 0.0002 0.0000

Amplitude

0.0012 0.0010 0.0008 0.0006 0.0004 0.0002 0.0000 53 54 55 56 57 58 59 60 61 62 63

53

54

55

56

57

58

59

60

61

62

63

Rotating frequency (Hz)

Time (s)

Rotating frequency (Hz)

Time (s)

No-load condition

Full-load condition

Condition Monitoring and Fault Diagnosis of Induction Motors

4. Bowed rotor shaft

Experimental conditions
Air-gap: 0.25 mm Deflection in mid-span: 0.075 mm

Condition Monitoring and Fault Diagnosis of Induction Motors

Characteristic frequency components: 1x, 2x

0.010

Normal Bend shaft

0.010

Normal Bend shaft

1x

0.008

0.008

Amplitude

Amplitude

0.006

0.006

0.004

0.004

2x

1x
0.002

2x

0.002

0.000 0 20 40 60 80 100 120 140 160

0.000 0 20 40 60 80 100 120 140 160

Frequency (Hz)

Frequency (Hz)

No-load condition

Full-load condition

Condition Monitoring and Fault Diagnosis of Induction Motors

5. Rotor misalignment (qualitative tests)

Experimental conditions
Bearing diameter: 40 mm Housing maximum diameter: 40.7mm Parallel misalignment
Rotor shaft

Geometrical center

Angular misalignment

Condition Monitoring and Fault Diagnosis of Induction Motors

Characteristic frequency components: double supply frequency, slip frequency No-load condition

Normal condition

Parallel eccentricity

Angular eccentricity

Condition Monitoring and Fault Diagnosis of Induction Motors

Full-load condition

Normal condition

Parallel eccentricity

Angle eccentricity

Condition Monitoring and Fault Diagnosis of Induction Motors

Feature extraction
Feature parameters: Mean, RMS, Shape factor, Skewness, Kurtosis, Crest factor
RMSF, FC, RVF, Entropy Estimations, Entropy error, Histogram (upper-bound and lower-bound)

Full-load condition

Upper-bound & Entropy error

Kurtosis & skewness

Condition Monitoring and Fault Diagnosis of Induction Motors

Training results of ART-KNN algorithm

160 140

100

No-load Full-load

No-load Full-load

95

Number of neurons

120 100 80 60 40 20 0 0.800 0.825 0.850 0.875 0.900 0.925 0.950 0.975 1.000

Success rate (100%)

90

85

80

75

70

65 0.800

0.825

0.850

0.875

0.900

0.925

0.950

0.975

1.000

Similarity coefficient

Similarity coefficient

Condition Monitoring and Fault Diagnosis of Induction Motors

Summary
Various motor conditions are tested under no-load, full-load conditions Faulty bearing (outer race) Rotor bar broken Rotor unbalance Bowed rotor shaft Rotor misalignment (parallel and angular)

The vibration analysis for motor faults is efficient tool The features of signals can be extracted through vibration signatures Classification algorithm, ART-KNN, are carried out to learn and classify the conditions. The results can reach 100% success rate.

Condition Monitoring and Fault Diagnosis of Induction Motors

Time Schedule
Content Month 1 2 3 4 5 6 7 8 9 10 11 12 Diagnosis system Efficiency Faulty bearing Rotor Eccentricity Faulty stator Feature extraction Feature selection Diagnosis system test Dealing with problem Unbalance Rotor, Bowed Rotor Experiments Signal acquisition and Feature extraction Vibration signal and stator current signal Data diagnosis (vibration & current) Diagnosis (ART-KNN) Others

Condition Monitoring and Fault Diagnosis of Induction Motors

CBM information flow

Modeling & Prognostics

. .
Sensing

. .

Data Fusion

Reasoning

Feature Classification Extraction