AIR GAP
Doug Swinskey
PdMA Corporation
Motor Reliability Technical Conference
May 9-11, 2006 Clearwater Beach, FL
Objectives
Discuss Air Gap Fault Mechanisms
Compare Lap Wound vs. Concentric
Analysis Techniques
Fault Mechanisms
Five Basic Types
Rotor O. D. is eccentric to axis of rotation
Stator bore is eccentric
Rotor and stator are round but do not have
the same axis of rotation
Rotor and shaft are round but do not have
the same axis
Any combination of the above
Fault Mechanism
Static Eccentricity
Soft foot
Cocked bearing
Dynamic Eccentricity
Loose bearing
Warped shaft
Fault Mechanisms
Uneven Magnetic
Pull
Increased Vibration
Possible Pull-Over
During Start Up
Rotor/Stator Rub
Fault Mechanisms
Uneven Magnetic
Pull
Increased Vibration
Possible Pull-Over
During Start Up
Rotor/Stator Rub
Pull-Over at Start Up
Appears as random
strikes on both the
stator and rotor
Magnetic pull acting
upon the rotor varies
as the square of the
difference
If the gap N X is twice
that at X then the
magnetic pull at X is
going to be 4X stronger
Analysis
MCE
Rotor Influence
Check (RIC)
EMAX
Eccentricity test
How do you interpret a RIC?
Sine
Do you see a sinewave
Possible Low Influence Rotor (LIR)
Characteristics
Repeated distortion in all three phases
Alignment
Is the graph misaligned across the page
Min/Max inductance of each phase over two pole
faces
Peak-to-Peak
Possibly a concentric wound rotor
Stator fault indicated
Alignment
What condition is indicated by
this RIC?
Misalignment
Peak-to-Peak Inductance
Note the change in
the peak-to-peak
inductance from the
first pole group to the
second.
Software Alerts
Does the motor have Lap or Concentric
wound windings?
Ind 1 to 3
Ind 2 to 3
Evaluate the
Peak-to-Peak
Single Pole Face
Inductive Imbalance
The Second Pole Face
Line Frequency
48 Hz
Eccentricity Test
VFD Application
48 Hz Harmonic Markers
Eccentricity Test
VFD Application
48 Hz Harmonic Markers
Eccentricity Test
VFD Application
Bars 82
Estimate bars
when the
speed is known
Pre/Post Overhaul Testing
Pre/Post Overhaul Testing
Motor was sent for overhaul/repair
Rotor was rebuilt
All critical dimensions were verified and
satisfactory
74 Rotor Bars
Pre Overhaul Testing
FP = 5.9 HZ
Pre Overhaul Testing
SWIRL EFFECT
Pre Overhaul Testing
Post Overhaul Testing
Post Overhaul Testing
What Happened?
After installation the pump was released for
operation. Unfortunately the pump was still
isolated from the system with the discharge
valve shut. The pump was estimated to have
operated in that condition for over a day. It
was discovered when the technicians
performing the EMAX tests went to inspect the
motor after seeing the eccentricity results.
Helpful Hints
Rotor Influence Check
Slow motors require an additional pole face
Use the balance of inductance to determine if
you should continue the test
Eccentricity Test
For VFD powered motors, strobe/tach speed
The X16 scale will fit 4 peaks
Summary