Testing of Rotating AC
machines - Part II
1. Routine tests
• The primary purpose of the routine test is to
insure freedom from electrical and
mechanical defects, and to demonstrate by
means of key tests the similarity of the motor
to a “standard” motor of the same design.
• The “standard” motor is an imaginary motor
whose performance characteristics would
agree exactly with the expected performance
predictions.
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2. Prototype tests
• The purpose of a prototype test is to
evaluate all the performance
characteristics of the motor.
• This test consists of the following tests in
addition to the routine tests:
1 – 90 1.8 %
91 – 375 1.5 %
Efficiency tests
• Efficiency is the ratio of the motor output
power and the motor input power.
Output
• Efficiency =
Input
Output
• =
Output Losses
•
Input Losses
• =
Input
• It can thus be calculated by a knowledge of
power input and power output, or of power
output and losses, or power input and losses.
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What is RIC?
• The Inductance measurements taken from
each phase of the stator windings and
compares them at different rotor
positions to further define the condition of
the rotor.
• This test is known as the Rotor Influence
Check (RIC).
• Figure shows us the results of a RIC test
performed on a healthy AC induction motor.
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Note that each of the three inductance patterns are 120o apart and travel
through two complete cycles over 360°. This occurs as a result of the
motor under test being a 4-pole motor. Each pole consists of 90o.
• By definition, air gap eccentricity is a mechanical
fault with the motor.
• There are several possible causes for the
Failure Mechanisms
presence of variances in the distance between a
rotor and a stator.
• The five basic types of air gap eccentricities
that can occur are:
1. Rotor Outside Diameter is eccentric to the axis
of rotation,
2. Stator bore* is eccentric,
3. Rotor and stator are round, but do not have
the same axis of rotation,
4. Rotor and shaft are round, but do not have the
same axis of rotation,
5. Any combination of the above.
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• The following are only a few of the
possible causes of an air gap eccentricity:
1. Incorrect mounting of the motor to
its bedplate can lead to an air gap
distortion.
• A loose or missing bolt allows shifting of
the motor’s mounting foot during thermal
expansion of the frame.
• This shifting over time could lead to a
distortion of the frame.
• The common term for a motor incorrectly
mounted is soft foot.
2. During construction of the motor, out-of-
roundness of either the rotor or stator will
lead to an air gap eccentricity.
• Industry standards: for total indicated
roundness should be performed at
different locations along the length of each
of these components.
• Couple measurements are at the
circumferences of each component,
depending on the speed and size of the
motor, there are recommended tolerances
from 5% to 20% variation in the air gap.
3. Eccentricity can develop due to incorrect
tensioning of drive belts coupled to a motor.
• Incorrect alignment could also lead to a
situation similar to this with both leading to a
bowing of the rotor during operation.
4. Distorted end bells, cocked bearings, or a
bent shaft will all cause an Air gap
eccentricity,
• During the manufacturing of the rotor, uneven
mechanical stresses could be introduced into
the cage and lamination stack.
• That will lead to bowing (bend) of the
completed rotor.
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• Increased levels of vibration due to the
uneven magnetic pull it creates between the
EFFECTS
circumferenceofofAIR
the gap
rotor eccentricity
and stator bore.
• These elevated levels of vibration can result in
excessive movement of the stator winding,
which could lead to increased friction and
eventually a turn-to-turn, coil-to-coil, or
ground fault.
• Additionally, this vibration can accelerate
bearing failure, which could seize the shaft
and overheat the windings or allow
additional movement of the shaft leading to a
rotor/stator rub (stroke).
• The uneven magnetic stresses applied to
EFFECTS
the rotor ofcoupled
AIR gapwitheccentricity
the increased
vibration will also contribute to
mechanical looseness developing in the
rotor.
• Any of these occurrences could lead to a
catastrophic failure (terrible) of the
motor, which could require a complete
rewind and possible restacking of the
iron.