PROCEEDINGS OF ICETECT 2011

Fault Analysis of Induction Motor

Mr.I.Kathir, Dr.S.Balakrishnan, R.J.Bevila
Asst. Prof Professor PG student

Dept of EEE, Mepco Schlenk Engineering College, Sivakasi. Abstract- A method for the fault diagnosis of a broken rotor bar in induction motor is presented. The method is based on the analysis of the magnetic flux of three-phase Induction motor. The purpose of this paper is the analysis of the inverter fed induction machine with broken rotor for diagnostic purposes. The features of magnetic flux of healthy conditions of a three phase induction motor are compared with that of the faulty conditions. Index terms Multilevel inverter, Finite element Analysis, Three-phase Induction Motor. I. INTRODUCTION An induction motor is simply an electric transformer whose magnetic circuit is separated by an air gap into two relatively movable portions, one carrying the primary and the other the secondary winding. Alternating current supplied to the primary winding from an electric power system induces an opposing current in the secondary winding, when the latter is shortcircuited or closed through external impedance. Relative motion between the primary and secondary structure is produced by the electromagnetic forces corresponding to the power thus transferred across the air gap by induction. The equivalent circuit of the induction motor is very similar to that for a transformer. Three-phase induction motor is the most commonly used motor in industrial application for its simple design, rugged construction, low initial cost and high efficiency [1]. Induction motors are available with torque characteristics suitable for a wide variety of applications. Moreover, squirrel cage induction motors have more advantages than wound type. Induction motors are the most widely used motors for appliances, industrial control and automation. Hence, they are often called the workhorse of the motion industry. When power is supplied to an induction motor at the recommended specifications, it runs at its rated speed. Many applications need variable speed operations. However, Induction Motors are susceptible to many types of fault, especially when supplied by the ac drives [2]. This is due to the extra voltage stresses on the stator windings, the resulting induced bearing currents, and the high-frequency stator current components caused by such drives. The most prevalent faults in AC induction machines are winding faults, unbalanced stator and rotor, broken rotor bar, Eccentricity and Bearing faults. Causes/Stresses leading to stator faults are Electrical stress, Thermal stress, Mechanical stress, Environmental stresses [3]. Practical methods for induction motor rotor fault diagnostics are analysis of power spectra, stator current space vector hodograph, stator phase current, stator voltage after supply disconnection or mechanical variables analysis. Increasing applications of sensorless controlled inverter fed drives with induction motors is the reason for developing new diagnostics methods. The results of fault studies help the machine designers to improve the fault tolerance as well the overall design of the machine drive system. For industrial processes, the Induction motor fault monitoring and diagnosis is important to identify motor failures before they become catastrophic and to prevent severe damage to induction motors. Undetected minor motor faults may cascade into motor failure, which in turn may cause production shutdowns. Such shutdowns are costly in terms of lost production time, maintenance costs, and wasted raw materials. In the past two decades, there has been substantial amount of research to provide new condition monitoring techniques for ac induction motors based on analyzing vibration signals, or signals other than currents. Vibration transducer is expensive and care should be taken into account for mechanical installation and transmitting the signal [4]. Similar problems exist while working with other sensors like speed and temperature. Interestingly, signatures of all signals are available on electrical terminals of electric machines including the vibration signals [5]. Current signals can easily be monitored for condition monitoring and control purposes. This paper describes the use of Finite element analysis to determine the flux distribution in the Induction motor. The paper describes a Multilevel Inverter, conventional design of induction motor and the broken rotor bar fault analysis of inverter fed induction motor. II. METHODOLOGY The AC input voltage is converted into DC intermediate voltage using a rectifier bridge. The large capacitor is used to remove the ripples present in the intermediate DC voltage. Then the pure DC voltage is converted to AC voltage using an inverter switching circuit. The rectifier is usually a three phase diode bridge, but controlled rectifier circuits are also used. The

978-1-4244-7926-9/11/$26.00 2011 IEEE

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AC output voltage is fed to the induction motor. Fig. 1 shows the representation of an AC drive incorporating inverter.

Fig. 1 Representation of an AC drive

III. MULTILEVEL INVERTER Induction motor is fed by a multilevel inverter to reduce the effect of harmonics in the stator current. Furthermore, Electromagnetic interference and the voltage stress across the inverter switches and load can be reduced because of increased levels of the output voltages compared with the conventional two-level inverters. Three phase, three level diode clamped topology of multilevel inverter is used in this paper because of its high efficiency. Fig. 2 shows the induction motor drive based on diode clamped multilevel inverter. 2(N-1) MOSFET switches are used in each leg. The gating signal for the MOSFET is generated by comparing the sine wave with carrier wave. It has two carrier waves since it is a three level inverter. i.e., N level inverter requires (N-1) carrier waves and (N-1) DC link capacitors are required. The diode clamps the voltage across the switch to one level and all diodes are selected as same type i.e., same voltage withstanding capacity. So they are called clamping diodes. The diode provides the forward path and feedback path to the current. The output voltage from inverter is given to the induction motor. Fig. 3 shows the stator current of inverter fed induction motor.

Fig. 3 Stator current of the Three phase induction motor

IV. FINITE ELEMENT ANALYSIS The induction motor is made up of the stator, or stationary windings, and the rotor. The stator consists of a series of wire windings of very low resistance permanently attached to the motor frame. As a voltage and a current are applied to the stator winding terminals, a magnetic field is developed in the windings. The rotor is comprised of a number of thin bars, usually aluminum, mounted in a laminated cylinder. The bars are arranged horizontally and almost parallel to the rotor shaft. At the ends of the rotor, the bars are connected together with a shorting ring. The rotor and stator are separated by an air gap which allows free rotation of the rotor. Table I lists the design specification of Induction motor.
TABLE I THE SPECIFICATION OF INDUCTION MOTOR

SPECIFICATIONS Power Voltage Speed Current A. Stator Inner Diameter:

KVA input Length of Stator

VALUES 5 hp 415 V 1430 RPM 7.95 A

( Q) = C 0 D 2 Ln s
(1)

Diameter of stator ( D) = 141 mm ( L) = 111 mm

B. Number of Turns:
Number of turns per coil ( T s ) = 3 kb 2 p m

= 42 turns/coil
where EMF constant
Fig. 2 Multilevel Inverter based AC drive system

(kb)=

V N

2 60 = 2.8515 v/rad/sec
3

(2)

Flux through core :

( m ) = B av L = 7.989 10 Wb

(3)

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C. Width Of Stator Teeth and Slot:

Width of stator tee th ( W ts ) =

m
1 .7 Ss Li p

= 6 mm where Iron length ( L i ) = 0.9[length = 0.0909 Width of stator slot ( W ss ) = Area of slot 36 depth = 5 mm of stator 0.01]

Fig. 4 and 5 show the stator and rotor of the designed induction motor respectively. Fig. 6 shows the cross-sectional view of the designed induction motor. The field analysis has been performed using a Computer Aided Design (CAD) package which is based on the variation energy minimization technique to solve for the magnetic vector potential. The vector potential can be post processed to obtain desired results such as the energy stored in the field, flux density, flux distribution, inductance, torque etc.

D. Stator Outer Diameter:

Stator Outer Diameter Depth of Stator Core ( D 0 ) = D + 2d ss + 2 d cs ( d cs ) = m = 25 mm 2B cs * L i As = 20 mm W ss (4)
Fig. 4 Stator of Induction Motor

Depth of Stator Slots ( d ss ) =

( D 0 ) = 230 mm where m Flux through L i Iron Length A s Area of each slot W ss Width of stator slot core B cs Flux density in stator core
Fig. 5 Rotor of Induction Motor

E. Air Gap Length: The air gap is kept to the minimum possible for the reason that the more the gap the greater magnetizing force required to establish a magnetic flux in it. It is also necessary to keep the gap uniform, which accounts for much of the mechanical rigidity of the shaft, frame and bedplate in a well designed motor. F. Rotor Diameter: The most common rotor is a squirrel-cage rotor. It is made up of bars of either solid copper (most common) or aluminum that span the length of the rotor, and are connected through a ring at each end. The rotor bars in squirrel-cage induction motors are not straight, but have some skew to reduce noise and harmonics. Diameter of Rotor (Dr) = Stator bore-(2 length of air gap) = 140 mm In the squirrel-cage Induction motor, the rotor winding consists of a series of bars of aluminum accommodated in the rotor-core slots, all bars being completely short-circuited at each end by a conducting ring. The starting and running characteristics of the motor are fixed by the design of the rotor winding. Because it is the simplest, cheapest and most robust types of motor, it is suitable for most drive requirements. Its rotor construction is without any slip-rings, commutator or brushes requiring no maintenance.

Fig. 6 Cross-sectional view of Induction Motor

The finite element solution gives the potential at the nodes. This information by itself is usually of little interest in machinery analysis. We use this information to compute useful quantities such as flux density and torque. The final grid contains 53612 elements and 26839 nodes. This allows us to compute fields in air gap and the torque more accurately. Fig. 7 shows flux distribution in the designed induction motor.

Fig. 7 Flux Distribution of Induction Motor

The current frequency associated with the rotating field is expressed as: fbdb = fs

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where fbdb = frequency of broken rotor, fs = supply frequency, l/p = 1,5,7,11,13....... are the characteristic values of the motor and s is the per-unit slip [6]. A broken bar causes several effects in induction motors. A well-know effect of a broken bar is the appearance of the so-called sideband components in the power spectrum of the stator current. These components affect the flux distribution in induction motor. Fig. 8 shows flux distribution in the induction motor with broken bar.
(a)

(b) Fig.10 (a) Healthy machine, (b) faulty machine

Fig. 8 Flux Distribution in the induction motor with broken rotor bar

The radial flux density in the air gap for the healthy and faulty Induction motor with their harmonics are calculated by FEM and shown in Fig. 9. It can be observed that flux density and vector potential of the machine with broken rotor fault becomes less sinusoidal and unsymmetrical. The magnitude of flux density harmonics magnify in the machine with broken bar fault. The harmonics of magnetic flux are more visible in the vector potential variable. Thus, the vector potential over air gap is obtained by FEM. Fig. 10 shows the calculated vector potential and its harmonic.

V. CONCLUSION The behavior of Induction Motor is studied under healthy and faulty conditions using Finite Element Method. This method classifies the broken rotor bar fault based on the finite element analysis of the three phase Induction motor. This method not only monitors the operating condition of an induction motor as healthy or faulty, but also can be used to diagnose the severity of the fault. The severity can be identified based on the number of broken bars. REFERENCES [1] B.Mirafzal and N. A. O. Demerdash, Induction machine broken-bar fault diagnosis using the rotor magnetic field space-vector orientation, IEEE Trans. Ind. Appl., vol. 40, no. 2, pp. 534542, Mar./Apr. 2004. [2] Aderiano M. da Silva, Richard J. Povinelli and Nabeel A.O. Demerdash, Induction Machine Broken Bar and Stator Short-Circuit Fault Diagnostics Based on ThreePhase Stator Current Envelopes, IEEE Transactions on Industrial Electronics, vol. 55, no. 3, pp. 1310-1318, Mar. 2008. [3] A. Siddique, G. S. Yadava, and B. Singh, A review of stator fault monitoring techniques of induction motors, IEEE Trans. Energy Convers.,vol. 20, no. 1, pp. 106114, Mar. 2005. [4] M. E. H. Benbouzid, A review of induction motors signature analysis as a medium for faults detection, IEEE Trans. Ind. Electron., vol. 47, no. 5, pp. 984993, Oct. 2000. [5] M.Haji and H.A.Toliyat, Pattern recognitionA technique for induction machines rotor broken bar detection, IEEE Trans. Energy Convers., vol. 16, no. 4, pp. 312317, Dec. 2001. [6] Cusido, J., L. Romeral, J. A. Ortega, J. A. Rosero, and A. G. Espinosa, Fault detection in induction machines using power spectral density in wavelet decomposition," IEEE Transactions on Industrial Electronics, vol. 55, no. 2, pp. 633-643, Feb. 2008.

(a)

(b) Fig. 9 (a) Healthy machine, (b) faulty machine

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