Professional Documents
Culture Documents
REVIEW
Subhasis Nandi
Hamid A. Toliyat
1. INTRODUCTION
197
U. VARIOUS -PIS
OF FAULTS
AND THEIR
DETECTION
TECHNIQUES
A. Bearing faults
The majority of the electrical machines use ball or rolling
element bearings. Each of these bearings consists of two
rings, one inner and the other outer. A set of balls or rolling
elements placed in raceways rotate inside these rings [Z].
Even under normal operating conditions with balanced load
and good alignment, fatigue failures may take place. These
faults may lead to increased vibration and noise levels.
Flaking M spalling of bearings might occur when fatigue
causes small pieces to break loose from the bearing.
Other than the normal internal operating stresses, caused
by vibration, inherent eccentricity, and bearing currents [39]
due to solid state drives, bearings can spoiled by many other
external causes such as
a) Contamination and corrosion caused by pitting and
sanding action of hard and abrasive minute particles or
corrosive action of water, acid etc.
b) Improper lubrication; which includes both over and under
lubrication causing heating and abrasion.
c) Improper Installation of bearing. By improperly forcing
the bearing onto the shaft or in the housing (due to
misalignment) indentations are formed in the raceways
(brinelling).
Though almost 4040% of all motor failures is bearing
related, very little has been reported in literature regarding
bearing related fault detection. Bearing faults might manifest
themselves as rotor asymmetry faults [Z], which are usually
covered under the category of eccentricity related faults.
Otherwise, the ball bearing related defect? can be categorized
as [I] outer bearing race defect, inner bearing race defect, ball
defect and train defect and the vibration frequencies to detect
these faults are given by,
f,[HzI = ( N I 2 )f,U- bd COS(P11d,I
for an outer bearing race defect
f,[HzI= ( N / 2 ) f , [ I + bdCOSV
) d, 1
for an inner bearing race defect
198
rotors),
b) Magnetic stresses caused by electromagnetic forces,
unbalanced magnetic pull, electromagnetic noise and
vibration,
c) Residual stresses due to manufacturing problems,
d) Dynamic stresses arising from shaft torques, centrifugal
forces and cyclic stresses,
e) Environmental stresses caused by for example
contamination and abrasion of rotor material due to
chemicals or moisture,
f) Mechanical saesse due to loose laminations, fatigued
parts, bearing failure etc.
Kliman [11], Thomson [12], Filippetti [13], Elkasabgy
[14] used spectrum analysis of machine line current (MCSA)
to detect broken bar faults. They investigate the sideband
components,f,, around the fundamental for detecting broken
bar faults.
(4)
fb = (1 f 2 s ) f
While the lower sideband is specifically due to broken bar,
the upper sideband is due to consequent speed oscillation. In
fact, [13] shows that broken bars actually give rise to a
sequence of such sidebands given by
fb = (1kZks)f , k=l,2, 3, ...
(5)
The motor-load inertia also affects the magnitude of these
sidebands. Other spectral components that can be observed in
the stator line current is given by 1111 and Gaydon [15]
-40.
199
300
-5.8
-f
6.2
6.4
lo
Frequency (Hz)
Time (Secs.)
182.6r
1
8
4w
350
Frequency (Hz)
Frequency (Hz)
6
8
O
.u
0,
;r 182.4
0
;
182.2
a
L-lw
v)
186
-150
6.1
6.2
Time (Secs.)
10
Frequency (Hz)
8
E
=z -5
1181.6
-10
-OW.
1W
50
6.1
6.2
v1
-50
6
6.1
6.2
Time(Secs.)
-3
-50
U1
-1W
-lW
0
50
-150
1W
0
Frequency (Hz)
10
Fig 2. Simulated plots of line current and speed (top row) and their
normalized spectra (bottom row) for the IWO end ngs panially broken. Slip
= 0.036.
-201
-40
0
-60
-80
-100
40
30
50
60
80
70
90
Frequency (Hz)
-2
-20
II
-40
-401
-60
-80
-100
40
30
50
60
70
80
90
-20
Q
0
2
-40
-60
-80
-100
30
40
50
60
70
80
90
Frequency (Hz)
Fig 3. Expcrimental plots of n o r d i z e d line cul~entspectra of healthy
machine (top) and with two (middle) and four bars partially broken (bottom).
Slip = 0.033. These and the four subsequent plots are obtained from a
machine that is similar to the one simulated. Faults were introduced by
drilling the bar*.
350
-40
0 -60
4w
450
n
(0
a -60
-1w
3w
350
4w
Frequency (Hz)
450
200
plots.
However, in practice, the current sidebands around
fundamental may exist even when the machine is healthy, as
can be seen in Fig 3. This could be due to uneven rotor bar
resistance because of the die casting process, rotor
asymmetry etc. Also components given by (5) may not show
any marked change (Fig. 4). Hence, at least for small motors,
it may be worthwhile to c o n f m the presence of broken bars
through the speed spectra Ojig.5).
D. Eccentriciry related faults
R =2p[3(mi.q)+r]
(9)
=If
f,
+kf,I ,
k = 1 , 2 , 3 ...
(10)
can also be detected for all machines (Fig.8). These low
frequency components also give rise to high frequency
components as described by (7). However, these components
are strong only for machines (Fig.9) whose pole pairs and
rotor slot numbers are given by (8) ( k = 1 ) and (9). For
machines described by (8) with k = 2 they are rather weak
(Fig.10).
Modeling based approaches to detect eccentricity related
components in line current have been described in [20,22].
The simulation results obtained through the models are also
well supported by permeance analysis and experimental
results. Fig.11 shows the experimental results for a similar,
skewed, 4 pole machine with R=44 and a nominal 38.46%
static and inherent dynamic eccentricity. The low frequency
sidebands that are present even under healthy condition did
not show appreciable change once eccentricity was
introduced. However, the high frequency components showed
moderate (around 5dB) increase.
Vibration signals can also be monitored to detect
eccentricity related faults. The high frequency vibration
components for static or dynamic eccentricity are given by
[17] using an equation similar to (7) (only the values of nd
and V are different). In case of mixed eccentricity, the low
frequency stator vibration components are given by,
f" =2f +f,
(11)
Time stepping finite element methods have been employed
recently to compare simulated results with experimentally
obtained static eccentricity components in line currents [19].
Static eccentricity has also been modeled using Winding
Function Approach [36].
Other approaches, such as monitoring the stator voltage
and current park's vector (Cardoso [Z3]) to detect eccentricity
in induction motor, can also be found in literature. Toliyat
and Al-Nanim [24] have provided simulation and
experimental results for synchronous machines with dynamic
eccentricity related faults.
III. ARTIFICIAL.
INTELLIGENCE
(AI) BASEDMACHINE
CONDITION
MONITORING
ANDFAULTDIAGNOSIS
In the recent past artificial neural networks (ANN), fuzzy
or neuro-fuzzy systems are being extensively used for speed,
torque estimation, solid state drive control of both dc and ac
machines [41]. However, they are particularly suited for ac
machines' applications where the relationships between
motor current and speed are non-linear.
These AI techniques are now being increasingly used for
condition monitoring and fault detection of machines
[4,13,41]. A neural net based fault diagnosis system utilizing
201
-80
v)
- 1 ~
-120
1200
-40 I
1250
1300
-50
U)
0.
-lW
50
1W
1400
-50
'
,
1250
1300
-120p
1200
ft21r
1450
DEC
-80
150
fundamental
4 f+f'
1350
.60t
-601
,.I
1350
, , ,..
-100
50
1400
100
150
1450
Frequency (Hz)
Frequency (Hz)
Fig.6 Simulated normalized plots of the line curmot spctra of a 3ph, 3hp, 60
Hz induction motor with 38.46% Static (top) and 20% dynamic eccentricity
(bottom) with Ips;R=43. Slip =0.029.
$.^
Fig.8 Simulated, normalized line current spedra of 3ph, 3hp, 60 Hz, skewed,
4 pole induction motors with different rotor slats and identical mined
eccentricity (SE =38.46%, DE=20%) machine around fundamental. From
top to bottomR=44,43,42. Slip=O.O29.
SEC
L -lW
-120
1150
-60
xc .1W
1200
DECI
. I
1300
1250
1150
1250
1300
1350
1400
-120t1
1200
1250
1300
1350
1400
,,
1450
DEC2
-120
1100
1200
1200
1250
1300
1350
1400
Frequency (Hz)
1450
Frequency (Hz)
Rg.7 Simulated normalized plots of the line current spema of a 3ph, 3hp, 60
Hz induction mota with 38.46% &tic with Slip= 0.029 (top) and 40%
dynamic eccentricity and Slip =0.00467 (bottom) with 2 e ; R=42. The
other static eccentricity component is suppressed due to loading effects.
202
Pig9 Simulated, normalized high frequency line current spectra of 3ph, 3hp,
60 Hz, 4 pole induction motors with different rotor slots and identical mixed
eccenllicity (SE ~38.46%DE=20%) machine. From top to bottom R 4 4 ,
43. Slip=0.029.
-n
Ln
1[0.5(R.1)(1-~)-1]
SEC1
I
.1W
.110
-120
1100
1120
1140
1160
1180
fI0.5(R+l)(l-s)+ll
.I20
1200
1250
1300
1350
1400
1200
IV. CONCLUSIONS
1450
Frequency (Hz)
Fig.10 Simulated, normlimed high frequency line cumen1 spectra of 3ph,
3hp, 60 Hz, 4 pole induction motors with 42 rotor slots and mixed
eccentricity (SE =38.46%,DII;ZO%) machine. Sli0;0.029.
0
-401
Psn
m^
p -50
n
-lW
0
0
50
1W
150
-40
8 -50
8n
ACKNOWLEDGMENT
1300 1350 1400 1450
Psn
-60
-80
-100
-1W
-120
50
1W
150
REFERENCES
Preprocessor
FFT & Averaging
Postprocessor
Time History
and Alarms
Rule-B ased
Frequency
Filters
Clutsering
Neural Network
Algorithm
203
I.
..
Mar. 1994.
1331 I. Penman, C.M. Yin, "Feasibility of using unsupervised learning,
artificial neural networks for the condition monitoring of electrical
machines", IEE Proceedings on Elect,. Power Applns., pp. 3 17-322,
Vol. 141, No.6, Nov.1994.
1341 F. Filipptti, G. Franceschini, C. Tassoni, Neural networks aided online diagnostics of induction mMor faults", Proceedings ofthe IEEE /AS Annual Meeting Conference, pp. 316-323, Vol. 1, Toronto,
Canada 1993.
P. L. Alger, The Nature of Induction Machine.<,Gordon and Breach,
New York, 1965.
H. A. Toliyat, M. S. Arefeen, A. G. Parlos, "A method for dynamic
simulation of *-gap eccentricity in induction machines," IEEE Trans.
Ind.Applm.,pp. 910-918, Vol. 32.No.4, July/Aug., 1996.
1371 S.Nandi. H.A.Taliyat, "Performance analysis of a lhree phase
induetion motor under abnormal operating conditions", IEEESPDEMPED. Franee, 1997.
I381 G. Kron, Equivalent circuit3 of electric machinery, John Wiley &
Sons. Inc.. New Yak, 1951.
1391 S . Chen, T.A. L i p . '"Bearing m e n t s and shaft voltages of an
induction motor under hard- and soft-switching inverter excitation",
IEEE Trans. Ind. Applm., pp. 1042-1048, Vol. 34, No. 5, Sept/O~t.,
1998.
1401 M. M. LiwschitZ " Field harmonics in induction moto~s",Trans. Am.
hf.
E k .Engg.,pp. 797-803,VOl. 61, Nov., 1942.
1411 P. Vas, Arrificinl -infelligence-based electrical machines and drives:
applications of fuzzy, neural, fay-neural and genetic algorithm
based Iedmiques, Oxford University Press, New York, 1999.
I421 M. Y. Chow, Methodologies of using neural network and fuzzy logic
technologies for m l o r incipient fault detection, World Scientific
Publishing Co. Pte. Ltd. Singapore, 1997.
143) B. Heller and V. Hamata, Harmonicfielde n e m in induction machine.
New York, 1977.
204