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Mathematical analysis of unbalanced magnetic


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Conference Paper · December 2013


DOI: 10.1109/CATCON.2013.6737499

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2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems

Mathematical Analysis of Unbalanced Magnetic Pull


and Detection of Mixed Air gap Eccentricity in
Induction Motor by Vibration Analysis using MEMS
Accelerometer
Maruthi.G.S.1 Vishwanath Hegde2
Department of Electrical and Electronics Engineering Department of Electrical and Electronics Engineering
Smt.L.V.Government Polytechnic, Hassan 573201 Malnad College of Engineering, Hassan 573201
Karnataka State, INDIA Karnataka State, INDIA
Email: maruthi.s.gujjar@gmail.com Email: hegde_mce@rediffmail.com

Abstract—Air gap eccentricity fault existing in the induction rotation can be anywhere between C1 and C2. Fig.1 provides
motor may be of the form static or dynamic or together known as better visualization of air gap eccentricity in induction motor
mixed eccentricity. Due to this, an unbalanced magnetic pull [1]. As the degree of static eccentricity increases, it can
(UMP) will be setup between stator and rotor. This can cause produce unacceptable levels of UMP in one direction, which
bearing damage, rubbing of rotor with stator and may develop result in shaft flexing and hence dynamic eccentricity.
unwanted vibration and noise, which may results in premature Dynamic eccentricity produces UMP that acts on the rotor
failure of the motor. In this context, this paper presents the which rotates at rotor rotational velocity. Both types of
mathematical analysis of unbalanced magnetic pull due to air gap eccentricity can cause excessive stress on the bearing and cause
eccentricity in induction motor. Experimental investigations have
wear, followed with harmful vibration [3]. This vibration is the
been carried out to detect mixed airgap eccentricity fault by
clear indicator of fault in motor. Analysis of the vibration
vibration signature analysis using Micro-Electro-Mechanical
Systems (MEMS) accelerometer under different operating
signals demands a more sensitive measurement.
conditions. The spectral analysis of motor vibration has been
carried out using radix-2 decimation in time Fast Fourier
Transform algorithm (DIT-FFT). The presence of side band
harmonic frequencies around fundamental component in the
motor vibration signal spectrum indicates mixed eccentricity
fault. The experimental results demonstrate that it is possible to
identify the mixed airgap eccentricity fault by vibration signature
analysis using MEMS accelerometer. A simple method has been
proposed to find the fault severity in the motor under variable Fig. 1. Visualization of air gap eccentricity [1]
load conditions due to mixed air gap eccentricity
The literature survey reveals the following facts. Subhasis
Keywords— Air gap eccentricity; Fast Fourier transform; Nandi et al. [1] have employed the terminal voltages of
MEMS accelerometer; Three phase induction motor; Unbalanced induction machines at switch off as medium to detect the
magnetic pull (UMP); Vibration signature. airgap eccentricity faults individually. This method is
independent of UMP and detection scheme works well for any
I. INTRODUCTION pole pair and rotor slot combination, unlike standard high
Air-gap eccentricity fault in an induction motor is the frequency-based detection schemes that work well only for a
condition of the unequal air-gap between the stator and rotor certain pole pair and rotor slot combination. The limitation
causing a force on the rotor that tries to pull the rotor from the with this method is, at the instant of switch off, the load effect
stator bore center. The fault can result from variety of sources will be zero. However, the magnitude of both SE and DE
such as stator core ovality, incorrect positioning of the rotor or depends on load. Hence, fault severity cannot be assessed using
stator at the time of commissioning stage, incorrect bearing this method. M E H Benbouzid [2] has reviewed the various
positioning during assembly, worn bearings, shaft deflections fault detection techniques. The spectral analysis namely
and so on [1-2]. In general, there are two forms of air-gap classical FFT, instantaneous power FFT, Wavelet analysis,
eccentricity: static eccentricity (SE) -where the rotor is Bispectrum, Park’s approach, Finite Element method (FEM)
displaced from the stator bore centre but is still turning upon its and Eigen value analysis, which makes use of motor current as
own axis i.e. C1 is the center of rotation, dynamic eccentricity medium to detect airgap eccentricity fault. David G. Dorrell et
(DE) - where the rotor is still turning upon the stator bore al. [3] have discussed online diagnosis of air gap eccentricity in
centre but not on its own centre i.e. C2 is the center of rotation three phase induction motors using stator current, vibration and
or both known as mixed eccentricity - where the center of air gap flux as medium of fault. It has been reported in the

978-1-4799-0083-1/13/$31.00 ©2013 IEEE CATCON2013


2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems
paper that SE will produce 100 Hz vibration component (for a piezo electric sensors in terms of its power consumption, on
50Hz supply) in addition to main field component and DE chip signal condition circuit, sensitivity, cost, size and band
produces non twice supply frequency terms fr (which cause width has been addressed in [14-16]. In the present work a
UMP), (2fs ± fr), 2(fs ± fr ) and 2 fr. It is found from the motor with a mixed air gap eccentricity (SE =10% and
experimental results that magnitude of SE increases with DE=30%) pre-manufactured (Test motor) employed to study
increase of load, where as magnitude of DE decreases with UMP and investigate airgap eccentricity under variable
increase of load. Hence the effect of UMP due to SE is more loading, single phasing and unbalance voltage conditions. The
than DE. Authors have reported that detection of UMP due to simple method of finding fault severity in test motor under
SE is difficult and it requires more sensitive device and sought variable load condition has been proposed.
more experimental investigation in this regard. Carlo Concari
et al [4] and Jawad Faiz et al [5] both have employed motor II. MATHEMATICAL ANALYSIS OF UMP DUE
current as medium to detect the mixed eccentricity. It is found TO AIRGAP ECCENTRICITY IN THE MOTOR
from experimental results that the amplitude of (fs±kfr) and Consider a two pole induction motor as shown in Fig. 2,
principal slot harmonic (PSH) frequency component increases where the rotor center coincides with stator bore center. Thus
with increase of static and dynamic eccentricity. But, with the length of the air gap is uniform and hence radial magnetic
fixed SE and by increase of load, it is found that amplitude of forces are uniform every where. The rotation of the rotor is on
side band harmonic frequency (fs±kfr) decreases. Spectral account of the formation of poles of opposite polarity on stator
analysis has been carried out by using time stepping finite and rotor which exerts a tangential force on the rotor. However,
element method in [5]. This method takes more time for a much stronger magnetic force of attraction takes place
computation and requires more computer memory. Hence on between the stator and the rotor poles acting along a direction
line fault diagnosis is difficult from industrial point of view. perpendicular to the rotor shaft axis. These forces therefore act
Mohammed Drif et al [6] have employed complex apparent radially. Flux density (B) distribution is uniform throughout the
power signals as medium to detect airgap eccentricity in air gap, as result the machine runs smoothly [3], [17].
induction motors. Both experimental and simulation results
have been presented along with fault severity factor. It is
noticed from experimental and simulation results that fault
severity increases with degree of either static or dynamic
eccentricity. Jawad Faiz et al [7] have reviewed different types
of eccentricity faults and their effects, consequences on the
health and behavior of the motor. Various indices used in the
non-invasive techniques are briefly discussed. The results of
this review are useful for manufacturers of fault diagnosis
systems in selecting proper indices for various fault conditions.
M. Sahraoui et al [8] have shown that DE frequency
components may exist not only around principal slot harmonic
but also around the fundamental component. B.L. Rajalakshmi
Samaga et al [9] have investigated mixed eccentricity in three Fig. 2. Radial magnetic forces in symmetrical machine
phase induction motor by modeling and simulation using
multiple coupled circuit and 2D-modified winding function The force of attraction between stator and rotor poles at the
theory. Instantaneous power, power factor spectra and Eigen point 1-2 (top side) in Fig.2 is
2
value analysis have been carried out to detect the eccentricity B2A μ 0 ⎛ A Tg ⎞
F1 = = .⎜ ⎟⎟ . A N
related frequency components and the results are compared. 2μ0 2 ⎜⎝ Lg ⎠
The fault severity quantification has not been computed for (1)
evaluating the life deterioration of motors other than Eigen where B = Flux density in air gap, Wb/m2 ; Lg = Length of
value based graph. air gap, mt ; ATg = MMF for air gap, A/m; D = Stator bore, m;
A = πDL/2, Area of each pole, m2; L = Axial length, m. If mmf
B.Liang et al [10] , Hassan oak et al [11] and C.Wang et al required for the iron parts is negligible, the total mmf is
[12] have been used vibration of the motor as a medium to consumed by the air gap i.e. ATg = AT. Since airgap length is
detect rotor bar damage and bearing fault detection. The uniform, the force of attraction between stator and rotor poles
authors have employed the conventional piezoelectric at the points 1-2, 3-4 are uniform, hence F1= F2. Therefore Eqn.
accelerometers for their studies. These accelerometers are (1) becomes
having limitation of measuring only short duration vibration B2A μ0 ⎛ AT ⎞
2

measurement. This is due to the fact that sustained F1 = F 2 = = .⎜ ⎟ .A N


2μ0 2 ⎜⎝ L g ⎟⎠
piezoelectric action will cause overheating of crystals and thus (2)
deteriorate their conversion capability. Hence vibration Forces F1 and F2 are equal and act in the opposite direction
monitoring using these accelerometers will not be accurate. and hence their resultant is equal to zero. Therefore, in a
Vishwanath Hegde et al [13] have employed vibration of the symmetrical machine there is no resultant radial magnetic pull
motor as a medium to investigate mixed airgap eccentricity in on the rotor. Eqn. (1) and (2) are derived by assuming the flux
motor under no load and full load conditions only. The fault density is uniform in the air gap. However, in induction
severity due to mixed airgap eccentricity has not been reported. machine flux density distribution is not uniform. Consider an
The advantages of MEMS accelerometer over the conventional elemental angle‘dθ’ at an angle θ from x-x axis, which is

208 CATCON2013
2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems
shown in Fig.2. The flux density in the elemental angle, B = direction on the rotor along AA´ axis. Therefore, pull per unit
Bm.Sinθ. The radial force acting on the elemental strip is area on the rotor along AA´ axis is
1 2 DL ⎡⎛ Lg ⎞
2
⎛ Lg ⎞ ⎤ , where Pm=
2

FRAD = . ( B m s in θ ) .d θ = Pm ⎢ ⎜ ⎟ −⎜ ⎟ ⎥
2μ0 2 ⎣⎢ ⎝ L g − e s i n θ ⎠ ⎝ L g + e s i n θ ⎠ ⎥⎦
1 (3) Pull per unit area with normal airgap (Lg) = B2/2µ0 N/m2.
FRAD = . B m 2 D . L . sin 2 θ .d θ
4μ0
The vertical component of the radial force is given by
1 N (4)
F vert = . B m 2 D . L . sin 3 θ .d θ
4μ0
Therefore, resultant magnetic pull per pole acting vertically is
π
1
Fres = . B m 2 D . L . ∫ s in 3 θ . d θ
4μ0 0

F =
B m 2
D L
N (5)
res
3 μ 0

If the integration is carried over the whole periphery i.e. 0 < (a)
θ < 2π, the resultant pull is zero.

1
F res = . B m 2 D . L . ∫ s in 3 θ . d θ = 0
4μ0 0

This is because the pull ⎛ Bm2 ⎞ of one pole is


⎜ DL ⎟
⎝ 3 μ 0 ⎠
balanced by an equal and opposite force on the other pole.
Fig. 3(a) shows cross sectional view of test motor used in the (b)
present work where the center of stator does not coincide with Fig. 3. Test motor (a) Cross sectional view (b) Rotor displaced vertically
center of rotor, which tends to create an air gap eccentricity. downward by 40%
The length of air gap at 1-2 (top side of Fig.3a) is Lg1, which On solving the expression within square brackets gives ≈
is longer than at 3-4 (Bottom side of Fig.3a) is Lg2. This 4 (e / Lg) sinθ as e is comparatively small. Therefore, pull per
would give rise to unbalanced magnetic pull which tends to unit area on the rotor along AA´ axis due to a pair of poles is
pull the rotor where the air gap between rotor and stator is e (8)
small. The pull is inversely proportional to square of length of = 4 Pm s in θ
Lg
air gap. The force of attraction between stator and rotor poles Vertical component of the pull per unit area is given as
at maximum air gap (at the point 1-2) in Fig.3 (a) is ⎛ ⎞
e
B 12 A μ0 ⎛ AT ⎞
2
(6) = ⎜ 4 Pm

s in θ ⎟ . s in θ

F1 = = ⎜ ⎟ .A N ⎝ L ⎠
2 ⎜⎝ L g 1 ⎟⎠
g
2μ0
where B1 = Flux density in the air gap at the top. 2B2 e (9)
= s in θ
2

Similarly, the force of attraction between stator and rotor poles μ 0 Lg


at minimum air gap at the point 3-4 in Fig.3 (a) is The area of strip = D L d θ . The total vertical pulls acting on
B 22 A μ0 ⎛ AT ⎞
2
(7) 2
F2 = = ⎜ ⎟ .A N the strip is e
2μ0 2 ⎜⎝ L g 2 ⎟⎠ = 2 Pm D L . . s i n 2 θ .d θ
Lg
where B2 = Flux density in the air gap at the bottom. It is
evident from the above that force F2 is greater than F1 since Lg2 Total pull acting on the rotor in the downward direction due to
< Lg1. Since F2 > F1, a resultant radial force acts on the rotor in pair of poles
the downward direction. This force or pull is called the e π
P p = 2 Pm D L . . ∫ sin 2 θ .d θ
unbalanced magnetic pull (UMP). For convenience, only two Lg 0
pole motor has been considered. The force equations can be
e (10)
extended to four, six pole and so on for study of unbalanced P = π P DL
p m
Lg
magnetic pull. Fig. 3 (b) gives the motor with rotor displaced
vertically downwards. Let e = displacement of rotor along π DL 2 e (11)
Pp = B
downward direction, D = Diameter of rotor, L = Length of 2μ0 Lg
machine core. Modified length of air gap at the top along Since A = πDL / 2, the unbalanced magnetic pull
vertical axis = Lg + e; Modified length of air gap at the bottom
along vertical axis = Lg - e; Referring to Fig. 3(a), consider a U M P = 2 . A.P e (12)
m
differential strip at an angle θ from horizontal axis x-x. Lg
Modified length of air gap at the top along AA` is Lg1 = Lg + e The Eqn. (12) can be extended to calculate UMP for
sinθ; Modified length of air gap at the bottom along vertical machine with any number of pole pair p and is given as, UMP
axis = Lg – e sinθ; There are two forces acting in the opposite due to p poles = Pole pair x Pp

209 CATCON2013
2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems

UMP = p 2. A. P e = p . A . P e (13) 2.5 kilo samples/second over span of 1 kHz, 0.5 kHz and 0.25
2
m
Lg
m
Lg kHz for 30 seconds have been used to study higher and lower
frequency range fault signals by using rectangular window.
or
⎛ B2 ⎞ where k = p . A .e
UMP ∝ ⎜
⎜ L ⎟⎟
.k
⎝ g ⎠
2 .μ 0
Further, in the case of machines, where the flux density
distribution is sinusoidal, it is possible to obtain expression for
UMP based on root mean square (RMS) value of flux density.
As B m , the Eqn. (13) becomes
B =
2
π DL e (14)
U M P = Pp = Bm2 Fig. 4. Experimental setup of the present work
4μ0 Lg
where Pp = UMP per pair of poles. From Eqn. (14) it is IV. RESULTS AND DISCUSSION
clear that unbalanced magnetic pull is directly proportional to The mixed airgap eccentricity fault in a three phase
square of flux density and inversely proportional to air gap induction motor has been studied under no load, half load, full
length. Hence, uneven flux density distribution in air gap load condition, single phase and unbalance voltage condition.
results in set up of vibration in motor. The results of vibration signature analysis have been presented
for various cases.
III. FREQUENCY ANALYSIS OF AIRGAP
ECCENTRICITY IN INDUCTION MACHINE A. Case: 1 Healthy motor, no load running condition.
The mixed airgap eccentricity (static and dynamic) fault V = 415 Volts, I = 0.6 Amps, N = 1490 RPM; s = 0.0063
frequency as described by [1-9] and [13] is
f mix = f s | 1 ± k . f r | , for k =1, 2, 3…. (15)
where fr =
(1 − s ) (16)
P
fr is the rotor frequency in Hz, s is slip, P is the number of pole
pairs. Eqn. (15) and (16) can be used to detect eccentricity
related fault signatures in both the line-current and the
vibration-related spectrum [3]. The advantage of eqn (16) is
that it does not require knowledge of the machine construction Fig. 5. Vibration signature under no load condition for healthy motor
and is valid for any combination of machine pole pairs and
rotor slot number in a machine [1, 9]. When a balanced three phase supply voltage is applied to
healthy induction motor with uniform airgap (Lg), uniform
The simple method to find the fault severity due to current flows in all the phases. This will set up a uniform
dynamic eccentricity (DE) and static eccentricity (SE) with magnetic field both in stator and rotor. As a result uniform
variable load condition is given in Eqn. (17) and (18). magnetic forces will develop radially as per Eqn. (2). Since the
magnetic pull is uniform throughout air gap, the net UMP is
Magnitude _ average _ of _ f s (1 ± f r ) (17)
% SFDE = x100 zero. The interaction of mmf in rotor circuit with stator
Magnitude _ of _ f s magnetic flux will produce steady positive motor torque, which
Magnitude _ average _ of _ fs (1± 2 fr ) drives the rotor in forward direction producing useful
%SFSE = x100 (18) mechanical output. A fine radial vibration will be setup in the
Magnitude _ of _ fs stator. The spectral analysis of vibration signal yields dominant
IV. EXPERIMENTAL SET UP FOR DETECTION OF 49.81 Hz frequency component with magnitude of 51.83 dB
and no side band harmonic frequencies fs(1 ± k fr) as seen from
AIR GAP ECCENTRICITY
Fig.5.
An experimental set up of present work shown in Fig.4
consists of motor with rating ; 1.5 HP, 3 phase, 415 V, 50 Hz, B. Case :2 Test motor - under no load running condition.
1440 rpm, 28 rotor bar, 36 stator slots with mechanical load. V = 410 Volts, I = 1.28 Amps, N = 1490 RPM s = 0.0063
Motor construction has been altered with 10% stator ovality
and 40% rotor eccentricity for mixed eccentricity fault analysis
which is as shown in Fig 3 (a) and (b). The instrumentation
includes MEMS accelerometer (MMA6270QT: two axis (X,
Y) accelerometer ±1.5 g / 2 g / 4 g / 6 g), a high resolution FFT
analyzer and a personal computer, connected to FFT analyzer
through RS-232cable. In the initial stage of present work,
Tektronics 100 MHz storage oscilloscope, which has built in
FFT analysis provision, is made use for carrying out FFT
operation on accelerometer output signal. The sampling rate of Fig. 6. Vibration signature of test motor under no load condition

210 CATCON2013
2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems
Referring to case-2, the spectral analysis of motor vibration as
shown in Fig.6 provides the side band frequency components
fs(1 ± fr) = (74.97, 25.03) Hz with magnitude of (19.23, 22.83)
dB due to DE and fs(1 ± 2fr) = (100.1, 2.406) Hz with
magnitude of (20.03, 19.63) dB are due to SE. The increased
level of vibration and noise are noticed in motor.
C. Case :3 Test motor - half load running condition.
V = 410 Volts, I = 2.0 Amps, N = 1430 RPM s =0.046
Fig. 9. Vibration signature of test motor under no load – single phasing

F. Case: 6 Test motor- unbalance voltage (UBV) condition


VRY=375Volts; VRB = 410Volts; VYB = 420 Volts s=0.0133;
IR = 0.5Amps; IY = 1.9Amps; IB = 1.7 Amps; N = 1480 RPM
Referring to case 5 and case 6, when a test motor operate
under single phasing and voltage unbalance, the flow of
negative sequence current will generate the pulsating torque.
Fig. 7. Vibration signature of test motor under half load condition Also, due to airgap eccentricity, flux density is more distorted
in the airgap. As per Eqn. (14), this will cause UMP and hence
Referring to case-3, as the load on the motor is increased to
vibration, noise setup in motor, which will be more as
50%, the effect of DE decreases where as the SE increases,
compared to case - 2 to 5. The dominant presence of 2fs =
which is found from Fig.7. As per Eqn. (14), non uniform
102.7 Hz with magnitude of -51.3 dB component is clear
distribution of flux density in the airgap leads to UMP and
indicator of single phase in motor.
develops vibration. The spectral analysis of vibration signal
yields fs(1±fr)=(73.98, 26.14) Hz with magnitude of
(18.5,18.85) dB are due to DE and fs(1 ± 2fr) = (98.03, 2.096)
Hz with magnitude of (24.85, 24.85) dB are due to SE.
D. Case: 4 Test motor - full load running condition.
V = 390 Volts, I = 3.0 Amps, N = 1400 RPM s = 0.0667

Fig. 10. Vibration signature of test motor under no load –unbalanced voltage

The spectral analysis under single phase condition shown in


Fig.9 yields the amplitude fs(1 ± 2fr) = (97.29, 2.589) Hz with
magnitude of (- 66.15, - 60.75) dB are due to SE. It is difficult
to identify the fs(1 ± fr) harmonic frequency components, which
are caused due to DE. However, spectral analysis under
Fig. 8. Vibration signature of test motor under full load condition
unbalanced voltage condition provides the unique signature as
Referring to case-4, as the load on test motor is further shown in Fig.10,which gives the amplitude of side band
increased to 100%, speed reduces, the current increases with harmonic components fs(1 ± fr) = (74.97, 25.15) Hz with
increase of loss, which leads to increase in the temperature, magnitude (14.55, 14.05) dB are due to DE and fs(1 ± 2fr) =
vibration and noise as compared to no load and half load (97.66, 2.343) Hz with magnitude of (25.65, 20.85) dB are due
conditions. But, the degree of UMP will be reduced due to the to SE.
fact that increase of load makes the rotor shaft assembly
sufficiently stiff about its rotation. As a result, uneven TABLE I. EXPERIMENTAL AND THEORETICAL VALUES OF FS(1 ± KFR)
COMPONENT UNDER VARIABLE LOAD, 1PHASE AND UNBALANCE VOLTAGE
distribution of magnetic flux density in airgap leads to the
UMP in machine as per Eqn. (14). The amplitude of side band
frequency components as found from Fig.8 are fs(1 ± fr) =
(73.98, 26.63) Hz with magnitude of (14.25, 14.66) dB, are due
to DE and fs(1 ± 2fr) = (97.66, 2.466) Hz with magnitude of
(26.85, 26.86) dB are due to SE. The above analysis shows
that magnitude of SE increases whereas DE decreases with the
increase in load as found from Fig.8.
E. Case :5 Test motor - single phase running condition
VRY=340 Volts; VRB=375 Volts; VYB=415Volts s = 0.0133;
IR =0 Amps; IY =1.95 Amps; IB =1.95 Amps; N =1480 RPM Table-I provides comparison of experimental and
theoretical values of side band characteristic frequency

211 CATCON2013
2013 IEEE 1st International Conference on Condition Assessment Techniques in Electrical Systems
component of test motor operating under variable load, 1-phase presence of side band harmonic frequency components along
and unbalance voltage condition. The theoretical values of fault with fundamental component fs(1±kfr) is a clear indicator of
frequencies as computed by using Eqn. (15) closely matches mixed airgap eccentricity fault in motors. It has been found
with experimental values. from experimental results that the side band frequency fs(1 ± fr)
are due to DE and fs(1 ± 2fr) are due to SE. This is due to the
TABLE II. AMPLITUDES OF FS(1 ± KFR) COMPONENT AND SEVERITY fact that in case of DE, the magnitude and fault severity factor
FACTOR(%SF) DUE TO DE AND SE (EQN.17 AND EQN.18).
decreases with increase of load but it increases with increase of
load in SE condition. Also, as the degree of SE and DE
increases, fault severity also increases. Presently research
work is in progress to investigate other mechanical faults in
induction motor using MEMS accelerometer.
Table –II provides amplitude of fs(1 ± kfr) component and
fault severity (%SF) due to DE and SE (Eqn.17 and Eqn.18) REFERENCES
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