Effectiveness of Vibration and Current

Monitoring in detecting Broken Rotor

Bar and Bearing Faults in an
Induction Motor

Presented by
T.CH. Anil Kumar
Research Scholar (QIP)
Reliability Engineering Centre
IIT Kharagpur.
at
6th International Conference of Power Systems (ICPS) –
2016, 4-6th March, IIT Delhi
 Outline of Presentation
• Introduction
• Literature Review
• Scope of Present Work
• Induction Motor Fault Diagnosis
• Experimental Set-up
• Results
• Conclusions
• References
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 Introduction
• Induction motors are subjected to various dynamic, thermal,
mechanical and electrical load conditions. These varied load
conditions leads to gradual wear in the induction motors.
• In general, faults in the induction motors are categorized as
mechanical and electrical types.
• Mechanical faults are of bearing faults, eccentric rotor, soft-
foot, looseness, rotor-stator rub; misalignment etc.
• Electrical faults are categorized as broken rotor bar, air-gap
eccentricity, inter-turn short, insulation failure, and shaft
induced voltage etc.

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 Introduction contd...
• In general features selected for fault diagnosis are classified as time-
domain, frequency domain and time-frequency domain.
Shaft or Couplings
2.4%
Rotor bars/rotor rings
4.7%
Not Specified
10.4%

External Device Bearings

15.6% 51.1%

Stator Windings
15.8%

Fig. 1. Induction motor component failure distribution [1].

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 Literature Review
• Fast Fourier Transform (FFT) of vibration and current signals for
the detection of broken rotor bar and bearing faults in induction
motors [2-13].
• Time – frequency domain techniques such as discrete wavelet
transform [14], higher order spectrums [15] are used for the
detection of these types of faults in induction motor.
• Time-frequency characteristics of the motor condition parameters
such as current, voltage, electromagnetic torque and speed for fault
detection is discussed in [16].
• Application of Ant clustering technique using time-domain features
is also reported in the literature for the detection of broken rotor bar
fault under varied load conditions [17].
• It is very difficult to detect faults such as broken rotor bar and
bearing defects in the induction motors at no load condition using
phase current spectrum [18, 19].

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 Scope of the Present Work
• To develop effective methods to diagnose any incipient fault present
in the induction motor due to poor manufacturing and faults induced
due to mishandling of the motor while in transportation by the
supplier before installation.
• It is always not possible to load the machine to its desired load
capacity during maintenance in the workshop test bench or a new
motor for inspection at site.
• This work also deals with the effect of star and delta connections on
the fault diagnosis of induction motor at no load condition, using
current and vibration signatures.

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 Induction Motor Fault Diagnosis
Broken Rotor Bar Detection Bearing Fault Detection
• In current spectrum [10-13, 20], • In vibration spectrum bearing faults can be
detected by the following relation [7-9, 22]

where, fbrb : Fault frequency related to

broken rotor bar, fs : supply frequency, k :
integer, s: slip of the motor.
• In vibration spectrum, any fault related to
rotor can be detected by monitoring the
synchronous speed (Ns) (or) rotor bar pass
frequency (RBPF) given by [21],
where, nb : no. of rolling elements, f :
rotational frequency, d : diameter of
rolling element, D : pitch diameter of
rolling element bearing, θ : contact angle
• In current spectrum, bearing faults can be
• where, fs : supply frequency, p : number detected using the relation [7-9, 22]
of poles in motor, n : number of rotor
bars.

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 Experimental Set-up
• Experimental set-up as shown in Fig. 2 consists of three 5hp (3-ϕ) induction motors
that are driven by direct online supply (DOL) with delta and star connections
separately.
• Experiments have been carried out at no load condition for each motor driven under
both delta and star connections at DOL supply. Samples of vibration and current
signals are captured continuously for the duration of ‘10s’ with the sampling rate of
16.384 kS/s.
Table 1. Technical specifications of the induction
motor.
Parameter Value (Unit)
Power 3.7 KW
Voltage 415 ± 10% V
Current 7.5 A
No. of Poles 4
No. of rotor bars 26
Drive-end Bearing SKF 6206 2z/C3
Fig. 2. Experimental Set-up

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 Results

Fig 3a. Current Spectrum of Healthy motor driven in Fig 3b. Current Spectrum of Broken Rotor Bar
DELTA connection. motor driven in DELTA connection.

Fig 3c. Current Spectrum of Bearing Fault motor driven in DELTA connection.

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 Results contd…

Fig 4a. Current Spectrum of Healthy motor driven in STAR Fig 4b. Current Spectrum of Broken Rotor Bar
connection. motor driven in STAR connection.

Fig 4c. Current Spectrum of Bearing Fault motors driven in STAR connection.

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 Results contd…

Fig 5a. Vibration Spectrum of Healthy motor driven in Fig 5b. Vibration Spectrum of Broken Rotor Bar
DELTA connection. motor driven in DELTA connection.

Fig 5c. Vibration Spectrum of Bearing Fault motor driven in DELTA connection.

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 Results contd…

Fig 6a. Vibration Spectrum of Healthy motor driven in Fig 6b. Vibration Spectrum of Broken Rotor Bar
STAR connection. motor driven in STAR connection.

Fig 6c. Vibration Spectrum of Bearing Fault motors driven in STAR connection.

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 Conclusions
• Finally we can conclude that vibration spectrum (FFT) is very effective in
detecting the broken rotor bar and bearing faults of induction motor under
no load condition whether the motor is delta or star connected.
• On the other hand, current spectrum fails even to identify the presence of
the seeded faults i.e. healthy and faulty current spectrums look alike even
the motor is delta or star connected.
• Also, it can be concluded that a minor decrease in the vibration amplitudes
at fault frequencies has been observed when the motors are connected in
star connection.
• The proposed methodology can be effectively used for quality control of
induction motors and also for carrying out fault diagnosis during regular
maintenance, inspection and installation.
• This shows the effectiveness of vibration spectrum over current spectrum
in early detection of broken rotor bar and bearing faults in an induction
motor at no load condition.

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 References
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THANK YOU

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