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Faults Detection in Induction Motor via Stator Current Spectrum Analysis

Conference Paper · November 2007

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 ICEEDT'07
International Conference on Electrical Engineering Design & Technologies, Hammamet Tunisia, Nov. 4-6, 2007

Faults Detection in Induction Motor via Stator Current

Spectrum Analysis

M. Messaoudi L. Sbita M. N. Abdelkrim

Research unit of Modelling, Analysis
and Systems control.
National Engineering School of
Gabes (ENIG)
Zrig 6029 Gabes, Tunisia.
messaoudi_stoupha@yahoo.fr
Research unit of Modelling, Analysis
and Systems control.
National Engineering School of
Gabes (ENIG)
Zrig 6029 Gabes, Tunisia.
lassaad.sbita@enig.rnu.tn
Research unit of Modelling, Analysis
and Systems control.
National Engineering School of
Gabes (ENIG)
Zrig 6029 Gabes, Tunisia.
naceur.abdelkrim@enig.rnu.tn

Abstract--This paper deals with the diagnosis of
induction motors (IM) with the so-called motor
current signature analysis (MCSA). The MCSA is one
of the efficient techniques for the detection and the
localization of electrical and mechanical failures, in
which faults become apparent by harmonic
components around the supply frequency. This paper
presents a summary of the most frequent faults and its
consequences on the stator current spectrum. A three-
phase IM model was used for simulation taking into
account in one hand the normal healthy operation and
in the other hand the broken rotor bars, the voltage
unbalance between phases of supply and the abnormal
behaviour of load. The MCSA is used by many
authors for faults detection in IM. But the major
contribution of this work is to prove the efficiency of
this diagnosis methodology to detect more than one
fault simultaneously, in normal and abnormal
conditions. Experimental results validate the
simulation work.
Index Terms--Induction motors, Fault diagnosis,
Motor current signature analysis.
1. INTRODUCTION
Induction motors play an important role in industry for
the rotating machine practice because of their hardiness
low costs and quasi-absence of maintenance.
Nevertheless, it arrives that this machine presents an
electric or mechanical defect. The faults of these machines
are varied. However the most frequent are [3]-[10]:
opening or shorting of one or more of a stator phase
winding, broken rotor bar or cracked rotor end rings,
static or dynamic air-gap irregularities, and bearing
failures. In order to avoid such problems, these faults have
to be detected to prevent a major failure from occurring. It
is well known that a motor failure may yield an
unexpected interruption at the industrial plant, with
consequences in costs, product quality, and safety. During
the past twenty years, there has been a substantial amount
of fundamental research into the creation of condition
monitoring and diagnostic techniques for IM drives.
Different detection approaches proposed in the literature,
those based on the Extended Park’s Vector Approach
(EPVA), which allows the detection of inter-turn short
circuits in the stator winding [13]. The EPVA is
appropriate for the stator windings monitoring. Çalis and
Çakir used the 2.s.fs spectral component in the stator
current zero crossing times (ZCT) spectrum as an index of
rotor bar faults [2]. However, the major deficiency for this
fault indicator, for low slip IM operating at no load
condition it may then be difficult to read its value. In [5]
authors studied the diagnosis of IM by pattern recognition
methods. This method consists in extracting features from
the combination of the stator currents and voltages. Some
of these features could be irrelevant or redundant.
Therefore, the Sequential Backward Selection (SBS)
algorithm is applied to the complete set of features to
select the most relevant. Then they used the k-Nearest
Neighbors (kNN) rules to monitor the IM functioning
states. This rule is applied with reject options in order to
avoid automatic classifications and diagnosis errors.
Didier et al., [4] employed the Fourier Transform of the
stator current and they analyzed its phase. It is shown that
the basically calculated phase gives good results when the
motor operates near its nominal load. For weak load, the
results obtained are not robust enough for the detection of
an incipient rotor fault. In [1] the authors used the
vibration monitoring methodology to detect incipient
failures in IM. Vibration monitoring system requires
storing of a large amount of data. Vibration is often
measured with multiple sensors mounted on different
parts of the machine. The examination of data can be
tedious and sensitive to errors. Also, fault related machine
vibration is usually corrupted with structural machine
vibration and noise from interfering machinery. To
overcome these problems Pöyhönen et al., used the
Independent Component Analysis (ICA) to compress
measurements from several channels into a smaller
amount of channel combinations and to provide a robust
and reliable fault diagnostics routine for a cage IM [7].
This paper is focused on the Motor Current Signature
Analysis (MCSA) approach. This technique utilizes
results of spectral analysis of the stator current (precisely,
the supply current) of an IM to spot an existing or
incipient failure of the motor or the drive system. It is
claimed that MCSA monitoring is the most reliable
method of assessing the overall health of a rotor system

ICEEDT'07 – JES © 2007 journal.esrgroups.org/jes

[12]. Unlike the greater part of techniques, MCSA can
provide the same indications without requiring access to
the motor.
2. FAULTS EFFECT ON STATOR CURRENT SPECTRUM
A. Broken Rotor Bars
It is well known that, under normal conditions of
working, a 3-phase symmetrical stator winding fed from a
symmetrical supply with frequency fs, will produce a
resultant forward rotating magnetic field at synchronous
speed and if exact symmetry exists there will be no
resultant backward rotating field. When rotor defect
appears, it creates in addition of the direct rotor field an
inverse field that turns to the speed -s.ωs. It is due to the
fact that the rotor currents are now direct and inverse
following the unbalance of resistances. It is the interaction
of this field with the one descended of stator windings that
induces an e.m.f. and current in the stator winding at (1-
2.s).fs. This cyclic current variation causes a speed
oscillation at twice the slip frequency 2.s.fs and finally,
this speed oscillation induces, in the stator current
spectrum, an upper component at (1+2.s).fs, and so on
[11]-[2]. Broken rotor bars therefore result in current
components being induced in the stator winding at
frequencies given by:
f bb = (1 ± 2.k .s ) f s (1)
Where: k = 1, 2, 3…, k ∈ N;
fbb : broken rotor bars frequency;
s : slip;
p : number of pole pairs;
fs : electrical supply frequency;
B. Unbalanced Supply Voltage
Asymmetrical stator faults (caused by stator winding
faults or asymmetrical phase supply voltages) are also
common in IM [9]. An asymmetrical stator system fault
was physically seeded in the test rig by decreasing one of
the three phase supply voltages. An unbalanced in the
supply voltage induces sidebands in stator current
spectrum of the IM at the following frequencies:
f u sv = (1 + 2.k ) f s (2)
Where: k = 1, 2, 3…, k∈ N.
fusv : unbalanced supply voltage frequency;
fs : electrical supply frequency;
C. Load Effects
The load torque variation induces components in the
current spectrum which coincide with those caused by a
fault condition. In an ideal machine where the stator flux
linkage is purely sinusoidal, any oscillation in the load
torque at a multiple of the rotational speed will produce
stator currents at frequencies of [3]-[8]:
⎡ ⎛1− s ⎞⎤ (3)
f lo = f s ± k . f r = ⎢1 ± k ⎜ ⎟⎥ fs
⎣ ⎝ p ⎠⎦
Where: k = 1, 2, 3…, k∈ N;
flo : load effects frequency;
fs : electrical supply frequency.
fr : mechanical rotor speed in hertz;
s : slip;
p : number of pole pairs;
D. Bearings Damage
Bearings deterioration is the leading cause of motor
failures. Bearings damages are often caused by
improperly forcing the bearing onto the shaft or in the
housing. Misalignment of the bearings is also a common
result of defective bearing installation. The relationship of
the bearing vibration to the stator current spectrum [3]-
[10]-[14] is:
f bng = f s ± k . f i , o (4)
Where: k = 1, 2, 3…, k∈ N;
⎡ Db ⎤n
f i , o = ⎢1 ± cos β ⎥ fr (5)
⎣ Dp ⎦ 2
n : number of bearing balls;
fr : mechanical rotor speed in hertz;
Db : ball diameter;
Dp : bearing pitch diameter;
β : contact angle of the balls on the races
3. SIMULATION AND EXPERIMENTAL RESULTS
A. Motor current signature analysis for broken rotor bars
detection
Rotor fault is simulated by adding extra resistance to
the single phase resistance of rotor circuit [6]-[2]-[15]. In
Fig. 1, spectrum of stator current under 75 % operational
load is given, respectively, for healthy motor, rotor
resistance increased 20 % of its rated value, and rotor
resistance increased 40 % of its rated value. Based on the
healthy motor spectrum in Fig. 1 (a), one can observe in
Fig. 1 (b) and (c), the apparition of sidebands around the
fundamental. These sidebands are the results of the defect
created in the rotor. Frequencies of these sidebands
correspond precisely to the mathematical relation
(1±2.s).fs given by (1). The amplitude and the number of
the sidebands frequencies components are proportional to
the amount of broken rotor bars.
TABLE I, shows the harmonic components of the
stator current under 75 % of rated load with two levels of
rotor asymmetry.
When the IM operates with no load Fig. 2 (a), the
algorithm of detection does not give any response. This
means that the jump located at the frequency (1±2.k.s).fs is
not detectable due to its low amplitude. The current which
crosses the rotor bars is not important enough to create a
consequent jump at this frequency.
 (a) (b) (c)
100 100 100

80 80 80

Stator current (dB)

Stator current (dB)

Stator current (dB)

60 60 (1-2ks)fs (1+2ks)fs 60 (1-2ks)fs (1+2ks)fs

40 40 40

20 20 20

0 0 0

40 50 60 40 50 60 40 50 60
frequency (Hz) frequency (Hz) frequency (Hz)
Fig. 1. Stator current spectrum under 75% operational load: (a) healthy motor, (b) Rr = Rr + 20%Rr,
(c) Rr = Rr + 40%Rr.

100 100

48.81 Hz
51.19 Hz
Stator current (dB)

Stator current (dB)

52.38 Hz
47.62 Hz
50 50

0 0

-50 -50
30 40 50 60 70 30 40 50 60 70
(a) frequency (Hz) (b) frequency (Hz)
100 100

54.85 Hz
45.15 Hz
47.7 Hz

52.3 Hz
Stator current (dB)

Stator current (dB)

40.3 Hz
45.4 Hz

59.7 Hz
54.6 Hz

50 50

0 0

-50 -50
30 40 50 60 70 30 40 50 60 70
(c) frequency (Hz) (d) frequency (Hz)
Fig. 2. Stator current spectrum with Rr = Rr +40% Rr: (a) with zero load condition, (b) with 25% load condition,
(c) with 50% load condition, (d) with full load condition.

TABLE I
used as an efficient indicator of faults degree if the load
effect is taken into account. The frequencies of the first
Harmonic components of the stator current two sidebands around the fundamental frequency for an
IM operating with a fixed number of broken rotor bars are
Frequencies 1,2 * Rr 1,4 * Rr 48.81 Hz and 51.19 Hz under 25 % of rated load, 47.7 Hz
(1 - 6.s).fs 44,75 Hz and 52.3 Hz under 50 % of rated load and 45.15 Hz and
(1 - 4.s).fs 46,70 Hz 46,50 Hz 54.85 Hz under full load. This means that the motor slip
(1 - 2.s).fs 48,35 Hz 48,25 Hz varied proportionally with the load.
(1 + 2.s). fs 51,65 Hz 51,75 Hz
(1 + 4.s). fs 53,30 Hz 53,50 Hz B. Motor current signature analysis for broken rotor
(1 + 6.s). fs 55,25 Hz bars and unbalanced supply voltage detection *
For an IM with a constant number of broken rotor bars
operated under different levels of operational load, it is In order to simulate unbalanced supply faults, a V0 drop
clearly seen in Fig. 2 that the amplitudes of the sidebands in one phase condition was created. Hence, the stator
around the supply frequency increase as the load torque voltage supply equations were changed as follows:
rises. Thus, this indicator component is sensitive to the ⎛ 2π ⎞
load variation. Therefore, it is not exactly reflecting the Vas ( t ) = 2 (V − V0 ) cos (ωt ) ; Vbs ( t ) = 2 V cos ⎜ ωt − ⎟;
⎝ 3 ⎠
fault degree. But, the amplitude of the sidebands can be
 ⎛ 2π ⎞ supply voltages. Fig. 3 (b) and (c), clearly, show that
V cs ( t ) = 2 V cos ⎜ ω t + ⎟.
(6)
⎝ 3 ⎠ symptoms of both unbalanced stator voltage supply
In Fig. 3 (a), new frequencies (1+2k).fs: (150 Hz; 250 (1+2.k).fs and broken rotor bars (1±2.k.s).fs appear in the
Hz) emerge in the current spectrum, due to the unbalanced stator current spectrum.
100
fs
3fs
Stator current (dB)

50

0 5fs

-50

-100
0 50 100 150 200 250 300
(a) frequency (Hz)
100
fs
(1-2ks)fs (1+2ks)fs
Stator current (dB)

50 3fs

0 5fs

-50

-100
0 50 100 150 200 250 300
(b) frequency (Hz)
100
fs
(1-2ks)fs (1+2ks)fs
Stator current (dB)

50 3fs

0 5fs

-50

-100
0 50 100 150 200 250 300
(c) frequency (Hz)

Fig. 3. Stator current spectrum for 20V drop of one phase voltage: (a) healthy rotor; (b) broken rotor
bars Rr = Rr + 20%Rr; (c) broken rotor bars Rr = Rr + 40%Rr.
C. Motor current signature analysis for faults detection in Fig. 4 depicts the current spectrum of an IM operating
motor operating under variable load condition under three different operational conditions (described in
TABLE II):
In this section, to show the behavior of the motor
operating under variable load condition, constant motor TABLE II
load used in the model is replaced with sinusoidal
changing load as shown in (7). Motor operating conditions

Tl ( t ) = 10 + 1. sin(154, 48 t ) (7) case (a) case (b) case (a)

The load amplitude is equal to the rated load and the - Symmetrical rotor - Asymmetrical rotor - Asymmetrical rotor
resistance. resistance. resistance.
load frequency is chosen as the assumption in section 2.3. - Variable load. - Variable load. - Variable load.
Current spectrum is given in Fig. 4. It is shown that the - Balanced supply - Balanced supply - Unbalanced supply
load variation produces sidebands around the supply voltage. voltage. voltage.
frequency equal to frequencies of fs ± k.fr components.
 100
fs
fs-fr fs+fr
Stator current (dB)
50
fs+2fr
fs-2fr
0 fs+3fr

-50

-100
0 20 40 60 80 100 120 140 160 180 200
(a) frequency (Hz)
100
(1-2ks)fs fs (1+2ks)fs
fs-fr fs+fr
Stator current (dB)

50
fs+2fr
fs-2fr
0 fs+3fr

-50

-100
0 20 40 60 80 100 120 140 160 180 200
(b) frequency (Hz)
100
(1-2ks)fs fs (1+2ks)fs
fs-fr fs+fr 3fs
Stator current (dB)

50
fs+2fr fs+3fr
fs-2fr
0

-50

-100
0 20 40 60
(c)
Fig. 4. Stator current spectrum for motor operating under variable load condition: (a) healthy motor; (b)
motor with broken rotor bars (Rr = Rr +40% Rr); (c) motor with broken rotor bars (Rr = Rr +40% Rr) and
for 44 V drop in one phase of the supply voltage.
In Fig. 4 (a), only the frequencies due to load
variations appeared in the stator current spectrum. In Fig.
4 (b), with the frequencies components due to load
variations, it appeared also sidebands around the
fundamental at frequencies (1±2.k.s).fs produced by the
rotor asymmetry. In Fig. 4 (c), frequencies due to load
variation, rotor asymmetry and unbalanced supply voltage
appeared simultaneously in the stator current spectrum.
The major efficiency of the MCSA was its ability to
detect multiple kinds of faults at the same time without
requiring access to the motor. However, the main
drawback of this approach, for low slip IM operating at no
load condition it may then be difficult to detect the
frequencies (1±2.k.s).f due to its low amplitude. Thus, the
sensitivity of the technique depends on the external load.
80 100 120 140 160 180 200
frequency (Hz)
The simulation results, done with different kind of
faults and different degrees of severity, shows the
effectiveness of the MCSA method to spot an existing or
incipient failure of the motor.
An experimental setup is built around a dspace 1104
layout board (DSPtms320) to validate the simulation
results. Fig. 5 illustrates the experiment results of the
stator current spectrum when the IM is operated under
different unbalanced supply voltages. It appears in the two
Fig. 5 (a) and (b), sidebands at frequencies (1+2k)fs. It is
clear seen that the magnitudes of these sidebands rose
when the drop in the supply voltage is increased. The
increasing in the magnitude of frequencies created by the
unbalanced supply voltage is clearer at the supply
frequency third harmonic (150 Hz).
 150

Stator current (dB) 100

fs
3fs 5fs
7fs
50 9fs

-50
0 50 100 150 200 250 300 350 400 450 500
(a) frequency (Hz)
150
Stator current (dB)

fs
100
3fs 5fs
7fs 9fs
50

-50
0 50 100 150 200 250 300 350 400 450 500
(b) frequency (Hz)

Fig. 5. Stator current spectrum for motor operating under unbalanced supply voltage: (a) Partial unbalanced (30 %
drop in one supply voltage phase); (b) Full unbalanced (cut of one supply voltage phase).
4. CONCLUSION in induction motors," Eng. Appl. of Artificial Intelligence, vol. 19,
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