Abstract— This paper presents a simple, non-electrical contact through shaft and bearing can generate higher temperature
approach to detect and analyze multiple faults in the roller in the bearing, which can create surface roughness known
element bearings of three phase induction motor by vibra- as electrical fluting [6]. This can initiate premature failure
tion analysis using microelectromechanical systems (MEMS)
accelerometer. The ability of the proposed method has been of the bearing. When an IM having bearings with general
investigated experimentally under no load, single phase and roughness or abrasion or surface pitting is continued to
unbalanced voltage conditions. The frequency analysis of motor operate in industrial process, the chances of leading to multi
vibration due to bearing fault has been carried out by fast Fourier point defect in weaker zones of outer race, inner race, balls
transform algorithm. The appearance of fault frequencies in and cage are more. This is known as multiple faults in the
vibration spectrum will indicate multiple faults in the bearings
and also the existence of side-band frequency components around bearing, which will result in dynamic air gap eccentricity
fundamental frequency component indicates air gap modulation in the motor. This can further lead to the development of
due to bearing fault. Experimentally obtained fault frequencies Unbalanced Magnetic Pull (UMP) causing rubbing of rotor
are compared with analytical values and found that both are with stator [7]. The vibrations set up in the motor due to
closely matching. This indicates that the proposed method can multiple faults are complex in nature and it requires accurate
be reliably employed to detect from simple to complex faults in
the bearings of induction motor using MEMS accelerometers. and reliable sensors for detection and diagnosis [4].
Traditionally bearing fault has been detected by monitoring
Index Terms— Fast Fourier transform algorithm, MEMS quantities such as current, vibration, temperature, acoustic
accelerometer, multiple faults, single phase condition, unbalance
voltage, vibration signature analysis. emission, shock pulse monitoring and so on. The review
and comparative study of the above methods are reported
I. I NTRODUCTION in [1]–[5]. The stator current samples of motor with
inner and outer race bearing fault have been analyzed by
B EARINGS are critical components of induction
motors (IM) and they play vital role in safe and reliable
operation of IM on which the industrial processes depend.
Park’s and Concordia approach in [6] and advanced Park’s
approach in [7]. The fault identification in these approaches is
The industrial motor reliability studies have shown that based on circle and elliptic patterns. It is difficult to identify the
about 51% of motor failure is mainly due to bearings alone. fault because the fault patterns may get distorted due to poor
Hence condition monitoring of bearings is very important power quality. The spectral kurtosis and envelope analysis of
from industries point of view [1]–[4]. There are many reasons stator current in [8] and statistical processing of the stray flux
for bearing failure which includes contamination, corrosion, measurement in [9] are employed to detect localized bearing
misalignment, improper installation and lubrication, undesired faults. The airgap modulation due to radial rotor movement and
electrical, mechanical and environmental stresses [5]. Also, load torque variations in a motor caused due to inner race and
due to unbalance supply voltage condition, there is an ball defect have been reported in [10]. The vibration, current
induction of negative sequence current from stator to rotor and acoustic sensors are employed for continuous bearing
via shaft and bearing. The flow of negative sequence current fault monitoring in critical applications by wireless sensor
networks [11]. This method has limitations of imperfect data
Manuscript received July 24, 2015; accepted August 26, 2015. Date of delivery, data loss in harsh industrial environment and higher
publication September 3, 2015; date of current version December 10, 2015. cost due to the use of multiple sensors. A wireless sensor using
The associate editor coordinating the review of this paper and approving it
for publication was Prof. Zeynep Celik-Butler. inductive coupling principle and a tri-axial accelerometer have
Maruthi G. S. is with the Department of Electrical and Electronics been employed in [12] to detect single point defect in outer
Engineering, Smt. L. V. Government Polytechnic, Hassan 573201, India, and inner race by using motor vibration as medium. The fault
affiliated with the Department of Technical Education, Karnataka, India
(e-mail: maruthi.s.gujjar@gmail.com). classification and various signature techniques employed for
V. Hegde is with the Department of Electrical and Electronics Engineering, analysis of single point defect in the races of bearing have
Malnad College of Engineering, Hassan 573202, India, affiliated with Visves- been reported in [13].
varaya Technological University (VTU), Belagavi, Karnataka, India (e-mail:
hegde_mce@rediffmail.com). The amplitude modulation technique has been employed
Digital Object Identifier 10.1109/JSEN.2015.2476561 to detect bearing fault in outer and inner race by
1530-437X © 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
146 IEEE SENSORS JOURNAL, VOL. 16, NO. 1, JANUARY 1, 2016
where g0 = constant air gap length in mm; e = e0 , or ei or eb vmult iple f ault (t)
are the relative degree of eccentricity introduced by outer race,
[v2,O R (t)+g O R (θ, t)] X [v2,I R (t)+g I R (θ, t)] X
inner race and ball defect at the instants of t = k/ f 0 , t = k/ f i =
and t = k/ f ball seconds; ωr = Angular frequency; ωcage = [v1,ball (t)+gball (θ, t)] X [v1,cage (t)+gcage (θ, t)]
fundamental cage frequency. (9)
148 IEEE SENSORS JOURNAL, VOL. 16, NO. 1, JANUARY 1, 2016
TABLE II
E XPERIMENTAL VALUES OF FAULT F REQUENCIES IN M ULTIPLE
FAULTS B EARING – N O L OAD C ONDITION
TABLE III
C OMPARISON OF T HEORETICAL AND E XPERIMENTAL FAULT F REQUENCY
Fig. 5. Comparison of healthy bearing under no load and full load condition.
TABLE V
E XPERIMENTAL VALUES OF FAULT F REQUENCIES IN M ULTIPLE FAULTS
B EARING – N O L OAD , S INGLE P HASE C ONDITION
TABLE IV
E XPERIMENTAL VALUES OF FAULT F REQUENCIES IN M ULTIPLE FAULTS
B EARING – N O L OAD , U N -BALANCE V OLTAGE C ONDITION Fig. 9. Comparison of magnitude of fault frequency of multiple faults
bearing.
Fig. 10. Comparison of multiple faults bearing with inner race defect bearing.
ACKNOWLEDGMENT
The authors would like to thank associate editors and
three other anonymous reviewers for their valuable com-
ments on the paper. Authors would like to express gratitude
to Sri V. G. Bhat, Managing Director, Nikhara Electrical
and Allied Technology, an ISO 9001 company, Bangalore,
for supplying three phase squirrel cage induction motor
to suit our research requirements. Also, special thanks to
Sri. Obaiah. O, Principal and Sri. Chetan Kumar, Technician,
Government Tool and Training Centre, Hassan, for introducing
bearing defects using Wire EDM, and provide accurate bearing
dimensions using state-of-the-art measuring instruments.
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