BULETINUL INSTITUTULUI POLITEHNIC IAI

TOMUL L (LIV), FASC. 5, 2004

ELECTROTEHNIC, ENERGETIC, ELECTRONIC

ELECTRICAL MALFUNCTIONS VIBRODIAGNOSIS AT THE

DIRECT CURRENT MOTORS
BY

CRISTIAN BANARIE
Abstract. The identification and finding of malfunctions through vibrodiagnosis
leads to the elimination of useless de-mounting and checking operations, having
positive effects in cost decreasing direction. In this work we present and highlight
the manifestation and identification way of some electrical malfunctions at direct
current motors in mechanical vibrations spectra.
Keywords: vibrodiagnosis, vibrations spectra.

1. Technical considerations
The direct current motors have a large application domain in transports and
industry and especially in pulp and paper industry. These applications were
imposed by the advantages offered by these motors in regard to those in
alternating current: a rigid mechanical characteristic, the easy speed adjusting in
terms of maintaining energy transformation efficiency at high levels, good excess
current capacity, etc.
As any dynamic plant these motors can be diagnosed through vibrations
analysis through vibrodiagnosis. If the special literature presents consistent
information regarding the mechanical malfunctions identification way at this types
of motors (mechanical looseness on the arbors, in the bearings and in fixing the
motors on bases, misalignments between the motors and the driven plants,
mechanical unbalance of the rotor, etc.), it is not generous with information
related to electrical malfunctions diagnostic way, certain domains completely
missing.
In this direction some experimental checked information will be presented,
through which we can easily diagnose a diverse range of motors electrical
malfunctions, but also feeding and command systems malfunctions. The authors
had in view, when analyzing and classifying these malfunctions, the close
connection between the effects produced by the electromagnetic fields over the
motors magnetic parts, and also the results of their interaction according to the
analysis concept cause-effect.
There are four main vibrations spectra analysis methods met and used:
- Analysis through the monitoring of vibrations amplitudes average values
offers clues upon malfunctions appearance without locating it;
- Temporal variation analysis of vibrations levels offers presuming information
about malfunctions and their causes;

CRISTIAN BANARIE

- Simple Fourier Transformers analysis offers precise information about the

causes of malfunctions appearance, especially the malfunctions which induce
repetition oscillations;
- Simple Fourier Transformers analysis of a filtered and demodulated vibration
signal for malfunctions, which manifest into vibrations through stochastic spectra.
We must mention that once an electrical malfunction occurs, others can
occur, too, of mechanical type, causing anomalous motor function and in
consequence affecting the plant. For this reason a lot of malfunctions types
manifested on different frequencies, identified during the analysis giving us clues
related to malfunction cause and place, can occur in the vibrations spectra
collected during the motors drive. We also make mention of the thing that the
electrical malfunctions are more difficult to be identified in regard to the
mechanical ones, requesting professionalism from specialized technique and
maintenance staff side.
2. Describing of malfunctions identification solution through vibrations
analysis
For the collection of direct current motors vibrations spectra we used a
collector-analyzer type MICROLOG CMVA 60, a product of SKF fig.1
which through portative magnetic transducers (a
large range of transducers are used according to the
parameters which need to be measured) measures,
collects and memorizes automatically or with
operators intervention the plants vibrations spectra
and allows a deep analysis in the hostile industrial
medium. It is capable to display on a screen (LCD)
the frequency spectra FFT (Fast Fourier Transform)
as well as the temporal spectra.
The vibrations parameters collected from
plants are: speed (FFT), acceleration (FFT and
temporal variation) and filters acceleration 50-1000
Hz, 500-10000 Hz with signals demodulation, the
obtained parameter being called by the special
literature enveloping.
After collecting and stocking of spectra by the collector-analyzer CMVA
60, these are transferred into a calculation unit where by the help of PRISM4
soft, intended for monitoring and analysis of vibrating and wave phenomena,
which join plants driving, are analyzed and the plants technical state is
diagnosed.
Based on the previous considerations four electrical malfunctions types will
be presented, identified and classified for continuous current motors.
The vibrations spectra analysis begins with the acceleration parameter
analysis, as data collecting is realized with accelerometers, this being the first

BUL. INST. POLIT. IAI, TOMUL L (LIV), FASC. 5

parameter to be measured, the others being calculated on this base.

Case 1. The malfunctions from the motors commutation system have as an
effect the introduction of specific vibrations in the entire system. The first
identifiable malfunction through vibrodiagnosis is caused by an incorrect trailer
plate position towards the neutral motor axis. This acts through the appearance of
sparks or even of a fire circle at the contact between brushes and collector, and
provokes an overheating and a dark-brown coloring of the collector. Hereby, these
induce effects acting at frequency high values (in collectors commutation
frequency domain), in the motors magnetic elements. The vibration spectrum
associated to such malfunction is represented in fig.2. The electrical motor from
which
the
vibrations
spectrum was
sampled has a
power of 75
kW
and
Un=440 V. The
electrical
motor has the
speed of 882
rot/min and the
associated
fundamental
frequency of
14,7 Hz. It has
a
collector
made of 36
bars and a plate with two pairs of brushes. The commutation frequency is the
product between the fundamental frequency and number of collectors bars,
reported to the number of brush pairs on the trailer plate. In this case a simple
mathematical calculation indicates a commutation frequency situated in the
frequency domain of 265 Hz. This type of malfunction manifests into the
vibrations spectrum (FFT acceleration) through amplitude increasing at high
values in the commutation frequency domain (fig.2), dominant towards any other
spectrum amplitude, and the appearance of its sidebands at quotes of over 25%
from fundamentals amplitude. We mention that at normal drive the harmonics do
not pass over 10-15% from the commutation frequency amplitude. Likewise in
the adjacent areas of the commutation frequencies there are no spectral bands, at
normal drive being only in the commutation area, increasing easily to its value
then decreasing, the number of spectral sidebands being of 4-5 bands on each
fundamental
side.
Case 2.
From the same

CRISTIAN BANARIE

category of malfunctions related to commutation on continuous current motors,

we present in fig.3 the electrical motor specific spectrum on which the collector is
clogged up with black-lead powder resulted from the friction between brushes and
collectors bars. The electrical motor from which the spectrum was sampled is
identical to that presented in the previous case with the same functional and
constructive parameters.
This type of malfunction acts in the vibrations spectrum (FFT acceleration)
through the appearance of sub harmonics belonging to the commutation frequency
fundamental fc with values of 1/3*fc, 2/3*fc, fc. We also identify in the vibrations
spectrum the side spectra belonging to the commutation frequency, which are
more centered to this one, and sidebands on both commutation frequency sides
with increased amplitudes. The cause of their appearance is exactly the increased
rotor current value as a result of the collectors channels clogging, but also the
aggravation of the contact between brushes and collector after the accretion of
black lead particles and copper oxides.
Case 3. We can also identify and diagnose through vibrations spectra the
malfunctions from the category of imperfect contacts between brushes and
continuous current motors collectors. Hereby, the vibrations spectrum (fig.4) in
acceleration FFT - for a continuous current motor, is of the same type with
those presented previously, and has imperfect contacts between brushes and
collector. The recognition of this type of vibrations spectrum malfunction is
realized in the domain of the harmonics superior to the commutation frequency.
For this the vibrations spectra collecting domain was extended for this case at 800
Hz, towards the previous cases when it was at 400-500 Hz. This malfunction acts
through the appearance of additional harmonics in the vibrations spectra,
belonging to the commutation frequency up to 3 4 * fc and without important
sidebands. The additional harmonics have values close to the commutation
frequency, their
level decreasing
with
the
increasing
of
their multiples.
We mention that
in fig.4 is not
accentuated but
the
second
harmonic,
as
this
domain
offers
enough
information
regarding the
malfunctions
cause.
Case 4.

BUL. INST. POLIT. IAI, TOMUL L (LIV), FASC. 5

Another malfunctions category, which can be identified and diagnosed through

this method, is related to feeding tension unconformities of continuous current
motors. Therefore, due to the fact that on adjustable drives the continuous current
motors are fed from controlled rectifiers or dc - dc converters, malfunctions may
appear on these equipments, which affect well motors functioning. In this case
the most usual situation is improper motors feeding due to conduction relative
periods of the devices operated through rectifiers or converters.
In the spectrum represented in fig.5 this type of malfunction acts through
the appearance of the feeding frequency fundamental (50 Hz) and its harmonics
(up to the 10th harmonic), mentioning that one of 2nd, 3rd or 6th harmonics higher in
amplitude than the network fundamental, a particularity related to the tension
rectifying way. The motor is of the same type as those presented previously and it
presents another malfunction, acting through superior harmonics of the rotary
frequency fundamental, caused by a light bearings loosening (backlash between
shaft and ball or ball and plate) through the appearance of the rotary frequency 15
Hz (900 rpm) and its multiples.
3. The advantages of the dc motors vibrodiagnosis
The diagnostic through the method of continuous current motors
malfunctions have the following advantages:
1. Motors maintenance and repairing costs reduction;
2. Repairs planning avoiding the accidental plants shut-downs;
3. Forecasting the optimum intervention moment;
4. Plants life and reliability increasing;
5. Companys end products costs reduction.
REFERENCES
1.
2.
3.
4.
5.

Constantin Bala, Electrical Machines, EDP, Bucharest, 1982.

SKF Reliability Systems, San Diego 2002 Condition Monitoring Ins.
PRISM4 for Windows - Quick Start Manual, San Diego 2000 Condition Monitoring Ins.
http://www.dliengieneering.com/vibman
Banarie Cristian, Dima Dorian, Vibrating diagnosis of the mechanical loosening on axles.
B.I.P.Iasi, Tomul L(LIV), Fasc.Vb, 2004.
VIBRODIAGNOZA DEFECTIUNILOR ELECTRICE LA MOTOARELE DE CURENT
CONTINUU
(Rezumat)

Identificarea si localizarea defectiunilor prin vibrodiagnoza conduce la eliminarea

operatiunilor inutile de demontare si verificare a utilajelor, cu efecte benefice in directia
reducerii costurilor. In sensul celor de mai sus, prin prezenta lucrare se vor prezenta si evidentia
modul de manifestare si de identificare a unor defectiuni de natura electrica la motoarele de
curent continuu in spectre de vibratii mecanice.