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New Methodology To Faults Detection in Induction Motors Via MCSA
New Methodology To Faults Detection in Induction Motors Via MCSA
coils short-circuits.
Abstract— This paper introduces a new methodology for Mechanical faults are commonly associated to rotor or rotor
analysis of faults in induction motors based on MCSA using the related damage. The most important mechanical failures are:
Fast Fourier Transform (FFT). The report describes the rotor broken bars and rings, bearings damage, irregular gaps
methodology used for determining the exact amplitude of the
(static and dynamics eccentricities), unbalances, refrigeration
harmonic fault, regardless of the sampling time used, thus making
data acquisition and subsequent analysis easier. Another troubles, etc.
advantage of this method is that it only needs for its In general, faults in electrical machines are dominated by
implementation the measurement of the stator current. failures in bearings and stator coils. Focused on asynchronous
motors with squirrel cage rotor statistics are the following [2],
Index Terms— Fault Detection; Induction Motor [6]:
Maintenance; MCSA,
• Bearings fault related: 41%
• Stator faults related: 37%
I. INTRODUCTION
• Rotor faults related: 10:
I N industrialized countries, induction motors are responsible
for the 40% to 50% of energy consumption [1]. Recent
studies indicate that 90% of the failures in machines occur
• Other problems: 12%
Failures Statistics
due to miss function of the internal components, such as the
main motor [1].
Many methods have been proposed for induction motors 12%
failure detection, from sensorless methods to injection of high 10%
Bearings
frequency current into the stator coil [1], [3] - [5]. 41% Stator
Rotor
A large number of techniques for monitoring and diagnosis
Others
of asynchronous motors are based on the analysis of the
frequency spectrum, resulting from the FFT, however the data
37%
acquisition time required is excessively high to implementate
in a industrial environment [6].
First of all, a brief description of the most important faults
in induction motor is presented in conjunction with a first Fig. 1. Failures statistics in induction motors.
classification of these failures. Then, the mathematical data
acquisition model is introduced. After that, monitoring and III. DATA ACQUISITION MODEL
diagnosis methodology is described. Finally, laboratory and
industrial tests are analyzed in order to validate the Considering a sufficiently high number of samples (eight
methodology. seconds of sampling time at 5 kHz of sampling frequency), we
have that the ratio a k of discrete Fourier series converges to
II. FAILURES IN INDUCTION MOTORS
the a k of continuing Fourier series.
Most failures in induction motors can be classified in two
main groups: isolation failures and mechanical failures [7]. In Taking a signal f (t ) = β sin(ϖt + θ ) , and x = ωt ,
[7], failures in asynchronous motors are briefly presented. then f ( x ) = β sin( x + θ ) . If k + y periods are sampled,
Isolation failures are commonly characterised by stator with k an integer, and y real, we have the following expression
for the k-th harmonic (taking into account a sufficiently large
number of samples):
This work was supported in part by the PDT of the Uruguayan Ministry of
Education and ALFEX S.A.
M. J. Castelli is with the CITEM of the University of Montevideo, 2πk + 2πy 2πk
1 − xj
∫ β sin( x + θ )e
Montevideo, C.P. 11300, Uruguay (e-mail: mcastelli@um.edu.uy). 2πk + 2πy
J. P. Fossati is with the CITEM of the University of Montevideo,
ak = dx (1)
Montevideo, C.P. 11300, Uruguay (e-mail: jfossati@um.edu.uy).
2πk + 2πy 0
M. T. Andrade is with ALFEX S.A. Montevideo, C.P. 11100, Uruguay (e-
mail: mandrade@ieee.org).
978-1-4244-2218-0/08/$25.00 ©2008 IEEE.
2
Real part of a k : Based on the last expression, we could see that when we
consider a entire number of cycles ( Ω = 0 or y = 0) we have
cos( 2 π y + θ + 4 k π ) cos( 2 π y + θ ) that β = 2 ak
− 4π ( y + 2 k )
−
4π y
(2) Being k the main harmonic, we can appreciate what
β
cos( θ ) k cos( θ )( 2 y + k )
happens with this and the others when y ≠ 0
− 4 π ( y + k )( y + 2 k ) + 4 π y ( y + k )
The function
2 ak
Imaginary part of a k : f ( y) = (7)
β
sin( 2 π y + θ + 4 π k ) sin( 2 π y + θ ) Lets see what happens with the main harmonic and the
−
4π ( y + 2 k ) 4π y (3) followings when y ≠ 0 .
β
sin( θ ) k sin( θ ) k As follows an alternative in order to asses the true
+ 4π ( y + k ) + 4π y ( y + k ) magnitude of the signal introduced by the failure is described
Taking into account that the k-th is the main harmonic:
If 0 < y < 0.5 the second main harmonic is the (k+1)-th.
And
If0 > y > −0.5 the second main harmonic is the (k-1)-th
β 2( y (( y + 2k ) cos(2πy + θ ) Calling Ψ to the relationship between the main harmonic
ak = − 2 cos(θ )( y + k )) cos(2πy + θ + 4kπ ) and the second main harmonic:
4π
− y (( y + 2k ) sin(2πy + θ )
ak
Ψ= (8)
− 2 sin(θ )k ) sin(2πy + θ + 4πk ) (4) a k ±1
− 2 cos(θ )( y 2 + 3ky + 2k 2 ) cos(2πy + θ )
1 sin(π y )
− 2 sin(θ )k ( y + 2k ) sin(2πy + θ ) + 2 2π y (1 − y )
1 Ψ= = (9)
(2(cos(θ )) + 1) y 2 y ( y + 2k ) sin(π ( y − 1)) y
+ 2(2(cos(θ ))2 + 1)ky + 4k 2 )
2π ( y − 1)
Taking the limit of a k when k tends to infinite: Since this, an expression for y (Ψ ) could be found:
β 1 1 1
limak = [− 2(cos(θ ) cos(2π +θ ) + sin(θ ) sin(2πy +θ ) −1)]2 y =
4π y Ψ +1 (10)
k →∞ .
(k ∈ Ν) In the other hand, for an N and T sufficiently large:
sin(πy) sin(πy )
=β (5) 2 ak = β (11)
2πy πy
If πy = Ω then: From the last two equations, we can deduce:
sin(Ω) a k 2π
lim 2 a k = β =β
Ω π
k →∞ (6) sin (Ψ + 1)
ψ + 1 (12)
(k ∈ Ν )
With
3
This gives the exact amplitude of the fault signal. It this 1− s
also possible to deduce the exact frequency the defect, f ec = f s .(r ± nd ). ± nws (16)
provided by: p
f ec = eccentricity frequency
1
k± f s = supply frequency
f = Ψ +1 r = number of slots
tm (13) nd = + −
1
Therefore, from (12) and (13), it is possible to deduce both,
p = pole pairs
the extent of the defect and its exact frequency of occurrence. s = slip frequency
Fig 2. shows the relationship between main and secondary n ws = 1, 3, 5…
harmonics taking into account a sufficiently large number of
samples. Bearing failures [9][10]:
f 0 = 0.4 ∗ n ∗ f rm
(17)
f1 = 0.6 ∗ n ∗ f rm
f 0 = lower frequency
f 1 = upper frequency
n = balls number
f rm = rotor mechanical frequency
2,5
2
Amplitude (%)
1,5
0,5
0
0 0,5 1 1,5 2 2,5 3 3,5
Nr of Broken Bars
Short-circuits study:
Fig. 4. FFT of the initial condition for broken bars. s = 0.0153 (1477 rpm)
f sc = 25.37 Hz
5
TABLE II
RESULTS OF SHORT-CIRCUITS
Frec (Hz) Amp (%) SC (%)
25.37 6,554 0
25.37 6,563 1,5
25.37 7,279 2,45
25.37 8,669 4,41
8,5
Amplitude (%)
7,5
6,5
0 1 2 3 4 5 In this particular case, it is no necessary to see the time-
Short-Circuit (%) evolution of the failure, due to the obviously differences
between spectrums of different motor phases.
Fig. 9. Short-Circuits fault evolution.
VII. CONCLUSIONS
A new methodology for monitoring and diagnosis of large
asynchronous motors is presented here. This methodology
6
gives encouraging results. It is possible from this technique to Juan Pablo Fossati (M’2008) was born in
determine the exact extent of the defect and the associated Montevideo, Uruguay on December 22, 1983. He
received the degree of Engineer from the
frequency. In this way, the study of the growth tendencies of University of Montevideo in 2008, and now he is
failures is easier. currently working in the electrical motors research
group in the research institute (CITEM) of the
VIII. ACKNOWLEDGMENT University of Montevideo.
X. BIOGRAPHIES