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Comparison of techniques based on current signature

analysis to fault detection and diagnosis in induction


electrical motors

Abrahão S. Fontes, Carlos A. V. Cardoso, Levi P. B. Oliveira.


Universidade Federal de Sergipe
Electrical Engineering Department
Aracaju-SE, Brazil
abrahaofontes@gmail.com, carlosvcardoso@gmail.com, lpedro@ufs.br.

Abstract— The wide use of electrical induction motors in In the same table, another point that can be highlighted is
industries throughout the world requires, increasingly, more the component that failed on the motor. In this, it is observed
precision in fault diagnosis. Techniques of predictive that 25.4% of the faults occurring in the stator, such as inter-
maintenance such as Motor Current Signature Analysis (MCSA) turn short circuit, and 15.4% occur in other motor's
and Motor Current Square Signature Analysis (MSCSA) are components, such as the eccentricity in the air gap. It is
used to detect and diagnose faults patterns, characterized by the important to note also in the Tab. V that, in most cases, the
stator current spectrum, in induction motors. In this article, these moment of occurrence of the fault is when the motor is
techniques are applied and compared for different faults in real operating.
motors, such as inter-turn short circuit in the stator winding and
eccentricity in the air gap. To assist in the comparison of these Faults such as inter-turn short circuit and eccentricity in the
patterns of the stator current spectrum with and without faults, a air gap, generally, are intrinsic to the motor, within a tolerance
theoretical model of a healthy electrical induction motor was range, due to the manufacturing process itself [3]. These, when
used, with the same values of the real supply voltages, which they are at this stage, are not impeditive for the motor's
generated the frequency spectrum patterns. The results operation. However, these types of faults can progress to the
presented in this article, which should be emphasized, point of allowing the motor becomes inoperable, if not have the
demonstrated that the techniques mentioned above were suitable proper follow-up [4].
for the cited faults, whose comparison between the techniques
showed the suitability of each one. The data presented in Tab. V reinforce the need of a quality
maintenance. This can be reached by the use of predictive
maintenance, because, as already mentioned, hereby is possible
Keywords—induction motors; predictive maintenance; to detect the type of fault that the motor has, even if it is in
MCSA; MSCSA; fault diagnosis. operation. Several predictive maintenance techniques have
been developed for use in electric motors. Early studies in this
I. INTRODUCTION
area were initiated in the 80's with the application of various
Electric motors are used on a large scale in various methods using temperature and vibration sensors for
industries and factories in the world. It is estimated that nearly diagnosing faults of different types of motors [5] - [10].
80% of all electric motors in operation are induction type [1]. However, the use of these sensors are delicate and expensive,
In this context, predictive maintenance stands out, because it is and, it is usually needed to access the motor to diagnose the
based on the use of non-invasive techniques that allow fault type [11]. Subsequently, it was noted that the analysis of
diagnosing faults in electric motors, even in operation. This is the stator current frequency spectrum of the motor could be
because, by predictive maintenance is possible to detect the used to diagnose the same type of fault without the need to
start of a fault in the electric motor before it develops to the access the motor [12] - [14]. Then, this analysis has become
point of stop its operation, due to irreversible damage that known as a Motor Current Signature Analysis (MCSA)
might happens. Thus, once diagnosed the fault, the electric technique [11]. Already in the mid of 90's, several case studies
motor can operate to the point of program an intervention on it. have been published using the MCSA in real motors [15] -
This can be done in a planned manner and with the less [17].
operating time stop, with the objective of minimizing costs. To
In the following decade, some more advanced techniques
confirm these concepts, studies show that the number of faults
have been proposed to improve the analysis of motor's faults,
in motors increase with decreased quality of maintenance on
such as: Extended Park Vector Approach (EPVA) [18], Park's
electric motors, see Tab. V in the Appendix. It is important to
Vector Square Modulus (PVSM) and Park-Hilbert Transform
note that this table is an adaptation of the tables 3.18, 3.29 and
(PVSMP-H) [19]. The great advantage of these techniques is
5.3 present in [2].
the possibility of using the electric current of the three phases
of the motor, instead of use of only one phase in the MSCA.

978-1-5090-5395-7/16/$31.00 ©2016 IEEE

74
This enabled that a larger amount of information was used for phases. The results of this may be the most undesirable
analysis. Recent researches applied more advanced techniques. possible, for example: lack of phase; short circuit between
They use artificial intelligence, neural networks and fuzzy logic phases; short circuit involving earth [25].
for pattern recognition by the stator current [20], [21].
III. THEORY FUNDAMENTS
In this work, the techniques that perform detection and fault
diagnosis through spectral analysis of the motor stator current For the techniques used, there are two patterns for detection
will be evaluated, which are: Motor Current Signature Analysis of the eccentricity in the air gap and inter-turn short circuit in
(MCSA) and Motor Square Current Signature Analysis the frequency spectrum of the motor current. Subsequently,
(MSCSA). These techniques are based on the analysis of the techniques are presented, individually and theoretical aspects
harmonics present in the electrical current frequency spectrum of its applications in each fault, including their characteristic
of one phase of the motor, when it has faults and doesn't have frequencies.
harmonic filters [22], [23]. Thus, it is possible to predict
A. MCSA
motor's problems, such as inter-turn short circuit and
eccentricity in the air gap. The basic theoretical fundament of the MCSA technique is
based on the capacity that the faults, whether electrical or
In applying these techniques, the influence of the mechanical, have to influence the magnetic flux in the motor
harmonics presents in the supply voltage, in some cases, air gap [26]. Moreover, this technique is the most used in
interfere in the analysis of the fault types, because some predictive maintenance for detection and diagnosis of faults in
frequencies can be coincident [3]. Thus, some researches use induction electric motors because of the ease of application and
the current and voltage signals together for fault detection. This its non-invasive characteristics [23]. The application of the
technique is known as the Instantaneous Power Method [24]. technique consists of: the real-time acquisition of stator current
Thus, this paper proposes to use the same values of the real values of only one phase of the motor; the use of
supply voltage, on a theoretical model of induction electrical transformation tools in the time domain to the frequency
machine, simulated on computer environment. This has as domain, for example the Fast Fourier Transform (FFT); the
objective to separate the contribution portion of the supply analysis of the harmonic frequency present in the spectrum.
voltage. This model also permits the use of a standard of stator Every fault in the electric motor has a standard in the frequency
current frequency spectrum of an ideal motor, that is, without spectrum, which is your current signature. This signature is
faults. characterized by presenting certain values at specific
II. TYPE OF FAULTS frequencies.

There are a great variety of types of faults in electric Eccentricity in the air gap
motors. In this work, only the faults of eccentricity in the air In applying of the MCSA technique, the sidebands in the
gap and inter-turn short circuit will be discussed, because they frequency of the voltage source [11] and their odd harmonics
are significant, as already mentioned. given by: 5, 7, 9, 11..., are analyzed. The eccentricity air gap
frequencies are given by:
A. Eccentricity in the air gap
 fecc1 = k fs ± m  fs  (1-s)/p 
The eccentricity in the air gap occurs due to differences in
the distance between the stator and rotor in its extension. These where fs is the frequency of the voltage source, s is the slip, p is
differences can be static or dynamic type. The static the number of pair of poles k1 = 1,5,7,9,11... and m is a
eccentricity occurs when the stator core is oval, originated in sequential integer number.
the manufacturing period, or even when it suffers from thermal
effort in operation. As for the case of dynamic eccentricity, is Inter-turn short circuit
related to defects in the rotor, which may be due to: In MCSA technique, the frequencies are given by [15]:
unbalancing; thermal warpage; eccentricity on the rotor  fsc1 = (k± m  (1-s)/p ) fs 
diameter. The eccentricity in the air gap can even be inserted
into a motor during a poor quality maintenance. This occurs where k2 = 1,3,5,7...
when there is an incorrect position of the rotor [4].
B. MSCSA
B. Inter-turn short circuit This technique was first presented by [23] and consists in
As mentioned before, among the types of faults in the analyzing the square stator current frequency spectrum.
stator, the inter-turn short circuit is one possible cause, and it According to the author [23], the technique has three steps:
usually happens frequently. This type of defect normally acquisition of stator current of a motor phase; calculating the
occurs when there are faults in the inter-turn insulation, which square of this current; frequency spectrum analysis of the
can be due to a poor quality of the material or errors during the calculated value. For healthy motors, this spectrum will consist
assembly of stator coils in the manufacturing process. Also, of a fundamental component in 2fs and a DC component
faults in inter-turn insulation occur because of contamination, located at the origin [23]. The main advantage of this technique
when the motor is in operation or maintenance. is that it allows the appearance of new frequencies in the
mentioned spectrum that are unnoticed in the MCSA technique
The inter-turn insulation faults can begin undetectable, [23].
however, during the motor lifespan, this can develop a short
among several turns of the same phase or even different

75
Eccentricity in the airgap IV. RESULTS
In MSCSA technique, for detecting the eccentricity in the In the application of techniques and analysis of the faults
air gap in the motor current frequency spectrum is observed the were utilized two real motors and a theoretical motor, which
sidebands at twice the voltage supply frequency [23] and it has data are in Tab. I. The flow of data acquisition from motors and
the following pattern: the application of techniques is illustrated in the block diagram
of Fig. 1.
 fecc2 = k 2 fs ± m fs  (1-s)/p 
For data acquisition, was used ScopeMeters Fluke 190-104
Inter-turn short circuit
and AC Current Clamp Fluke i200s in the sampling frequency
Likewise, for inter-turn short circuit fault analyzes, the of 6250 Hz, that is, sampling every 0.16 ms. 30000 samples
current frequency spectrum at twice the voltage supply were collected for each motor, all these without load, with
frequency [23]: voltage applied at 60 Hz. The finite element method with a step
 fsc2 = (2 k± m  (1-s)/p ) fs  of integrating of 0.0001 was used to simulate the theoretical
motor model. The application of techniques and analyzes were
C. Theoretical Model of Induction Electric Machine performed on computing environment.
The theoretical model used is based on the "dq0 The voltages collected from the supply source of the real
transformation" [27] or the known Park transformation. This motors were applied on the theoretical model, for this to be the
type of transformed was adopted, because of the analytical closest to reality. Thus, it was considered a range in the voltage
resolution of the equation system of AC current electric frequency spectrum that includes the most significant
machine becomes impractical when the coefficients vary as a harmonics, according to Tab. II. The values of the harmonics
function of time [28]. In this way, a transformation of variables were compared with the limits of IEEE Std 519 [30] for
that enable a simpler resolution than the real variables is analysis of the quality of the supply source. Note on the Tab. II
necessary [28], [29]. Thus, to obtain the electric motor current that the values are well below the standard limits.
by a known voltage, it starts from the flux linkage equations
and their own and mutual inductances of electric machine [28], The patterns of the stator current frequency spectrum of the
that is: ideal motor, with the supply voltage mentioned above, are
illustrated in Fig. 2. Thus, two standards were generated: the
 ds123/dt = vs123 – Rsis123  current frequency spectrum and the square current frequency
 dr123/dt = vr123 – Rrir123  spectrum. Both, in Fig. 2, and the upcoming graphs are
normalized by the largest amplitude.
 is123 = (r123  Lm – s123  Lrr)/(Lm Lrr  Lss)
2

 ir123 = (s123  Lm – r123  Lss)/(Lm Lrr  Lss)
2

where: the subscript s123 or r123 indicates a column vector of
the phases of the stator or rotor, respectively; v is voltage; i is
current; R is resistance; λ is the flux linkage; Lss is self-
inductance of the stator coil; Lrr is self-inductance of the rotor
coil; Lm mutual inductance.
It is possible to simplify the three-phase machine model
foregoing, by “dq0 transformation” generic [28], such that:
 xdq0 = P -1  x123 
-1
Given that the transformation matrix P is given by: Fig. 1. Flow of detection and diagnosis of faults in motors

1⁄√2 1⁄√2 1⁄√2 TABLE I. DATA OF THE ELECTRIC MOTORS


cos(𝛿𝑔 − 4𝜋⁄3) ] 
2
𝑃 −1 = √ × [ cos(𝛿𝑔 ) cos(𝛿𝑔 − 2𝜋⁄3)
3
Theoretical motor Real motor 1 Real motor 2
− sin(𝛿𝑔 ) − sin(𝛿𝑔 − 2𝜋⁄3) − sin(𝛿𝑔 − 4𝜋⁄3)
Parameters Value Parameters Value Parameters Value
where g is the angular difference between direct axis and Lrr (H) 0.386 P (kW) 2.2 P (kW) 1.5
motor reference phase [28]. Lss (H) 0.386 V (V) 480 V (V) 440
Lm (H) 0.363 I (A) 3.7 I (A) 3.08
Therefore, the equations of the three-phase machine model Rss (Ω) 5.793 Poles 4 Poles 4
can be converted to a simplified two-phase model by applying Rrr (Ω) 3.421 n (rpm) 1690 n (rpm) 1755
this transformation matrix [29]. As this work is based on 𝛿g (°) 0
diagnosis and detection of faults in electric motors through the
analysis of the electric motor stator currents, the equations of TABLE II. PERCENTAGE OF VOLTAGE HARMONICS AND THEIRS LIMITS
the machine model should emphasize the stator currents. Thus, IEEE Std 519
Harmonics %
the equations used are given by: limits [12]
3a 0.49 3%
 isdq0 = (rdq0  Lm – sdq0  Lrr)/(Lm2Lrr  Lss)  5a 0.44 3%
7a 0.07 3%
 irdq0 = (sdq0  Lm – rdq0  Lss)/(Lm2Lrr  Lss) 

76
Fig. 2. Stator current pattern of ideal motor: (a) current frequency Fig. 3. MCSA – Eccentricity in the airgap.
spectrum and (b) square current frequency spectrum.

It is noted in the Fig.2 (b) that the frequency corresponding


to twice the harmonics in Tab. II are reduced. This is due to
small amplitude that present in the square current calculation.
In the same figure, the frequencies 240 Hz, 360 Hz and 480 Hz
were highlighted by being derived from the product between
the fundamental frequency, 120 Hz, and the 3rd, 5th e 7th
harmonics, respectively.
A. Eccentricity in the airgap fault analysis
Then, the analysis results of the eccentricity in the air gap
fault are presented, using the previously mentioned techniques.
MCSA technique
The eccentricity in the air gap fault is present in the real
motor 1 from Tab. I. As mentioned, the data collection was
done with the motor current at no load, ie, the slip s is very
small [31]. Thus, the frequency fecc1, in (1), for p = 2, k1 = 1 and Fig. 4. MSCSA – Eccentricity in the airgap.
m = 1,2,3,4 are 29.95, 90.03, 120.2, 149.7 and 180.2 Hz,
respectively. The current frequency spectrum is shown in Fig. Note that in Fig. 4, the side bands of the frequency 120 Hz,
3. Note that, when m = 1, fecc1 assume two values: m11 and which are m31, m21, m11 e m12, are the most significant when
m12 shown in Fig. 3. compared with the square current frequency spectrum pattern
Note that the current frequency spectrum of Fig. 3 shows of the ideal motor in Fig. 2 (b).
significant frequencies for this type of fault only on the Comparatively, the MSCSA technique allowed the
frequencies m11 and m12. This is observed as compared with appearance of new frequencies in the spectrum that were
the current frequency spectrum pattern of the ideal motor unnoticed in the MCSA technique. It is noted also that the
illustrated in Fig. 2 (a). same frequencies between the two techniques were more
MSCSA technique evident in Fig. 4.
The square current frequency spectrum is illustrated in Fig. B. Inter-turn short circuit
4. The frequencies of fecc2, in (3), for p = 2, k1 = 1 and m = The results of the analysis of the inter-turn short circuit fault
1,2,3,4,6,8 are 29.95, 60.08, 90.03, 150.1, 240.1, 300.2 and using same techniques applied in the eccentricity in the air gap
360.3 Hz, respectively. Note that, when m = 1, fecc2 assumes fault are shown below.
two values: m11 and m12 illustrated in Fig. 4. The frequencies
m21 and m31 in Fig. 4 are related of the subtractive part of (3) MCSA technique
for m = 2 and 3, respectively. The inter-turn short circuit fault is presented in the real
motor 2 in Tab. I. The frequencies characteristics of this fault,
to the MCSA technique, are obtained in (2) and assume the
values shown in Tab. III. The current frequency spectrum is
shown in Fig. 5.

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TABLE III. MAIN CHARACTERISTICS FREQUENCIES FOR INTER-TURN
SHORT CIRCUIT ON THE MCSA TECHNIQUE.

k2 = 1
m = 1 (m11) m = 2 (m12) m=3 m = 4 (m14)
89.26 Hz 119.8 Hz 150.7 Hz 180.1 Hz
k2 = 3
m=1 m = 2 (m32) m=3 m = 4 (m34)
150.7 Hz 239.9 Hz 89.26 Hz 300.2 Hz
k2 = 5 k2 = 7
m = 4 (m54) 420 Hz m = 4 (m74) 540.2 Hz

Fig. 8. MSCSA – inter-turn short circuit.

Similarly, as shown earlier, the terms on parentheses in Tab.


IV above are used in Fig. 6 to emphasize the characteristic
frequencies and their amplitudes.
It is observed in Fig. 6 that some of the frequencies that
characterize this type of fault are m11, m12, m13, m321 and
m322, because these do not appear in the square current
frequency spectrum pattern of the ideal motor illustrated in Fig.
Fig. 5. MCSA – inter-turn short circuit.
2 (b). It can also be observed that in the frequencies coincident
The terms in parentheses in Tab. III above are the points with this same pattern, this fault type shows higher and much
used in Fig. 5 to highlight the characteristic frequencies and more significant amplitudes. These values are highlighted in
their amplitudes in the graph. points m14, m58 and m34 in Tab. IV and in Fig. 6.
In the same way of the eccentricity in the airgap fault, the
Fig. 6. It can be seen from Fig. 5 that the frequencies
MSCSA technique enabled the appearance of new frequencies
significant to this type of fault, which are not coincident with
in the spectrum in Fig. 6. However, both techniques showed
the voltage harmonics, are m11, m12 and m32. It is noted also good results in the detection and diagnosis of this fault. This is
that, this type of fault, has bigger and very significant because the amplitudes in the characteristics frequencies have
amplitudes at the harmonics coincident with the voltage in Tab. highlighted values, as can be seen in Fig. 5 and Fig. 6.
II. These values were highlighted in points m14, m34 and m54
in Tab. III and in Fig. 5. These observations are made, V. CONCLUSION
comparatively, with the current frequency spectrum pattern of
the ideal motor illustrated in Fig. 2 (a). In this work two predictive maintenance techniques were
presented: MCSA and MSCSA. Both were applied in real
MSCSA technique motors, in order to detect and diagnose the faults of type
eccentricity in the air gap and inter-turn short circuit. A
Fig. 7. The characteristics frequencies of inter-turn short theoretical model of induction electric motor was used for the
circuit fault for the MSCSA technique were calculated from (4) generation of frequency spectrum patterns with the same
and are presented in Tab. IV. The square current frequency supply source voltage that have been applied in real motors.
spectrum of this same fault is illustrated in Fig. 6. These patterns were used to assist in the comparative analysis
between the frequency spectrum with and without faults. The
TABLE IV. MAIN CHARACTERISTICS FREQUENCIES FOR INTER-TURN goal was to evidence the characteristic frequencies to the faults
SHORT CIRCUIT ON THE MSCSA TECHNIQUE.
and separate the contribution portion of the amplitudes of the
k2 = 1 harmonics present in the supply source.
m = 1 (m11) m = 2 (m12) m = 3 (m13) m = 4 (m14)
90.79 Hz 59.89 Hz 29.37 Hz 239.9 Hz The results showed that the MSCSA technique enables the
k2 = 3 appearance of new frequencies in the spectrum. This was
m = 2 (m321) m = 2 (m322) m=3 m = 4 (m34) observed in Fig. 4 and Fig. 6. This technique emphasizes, more
300.2 Hz 420 Hz 270 Hz 480.3 Hz significantly, the amplitudes of the characteristics frequency of
k2 = 5
m = 4 (m54) 360 Hz the faults, as illustrated in the mentioned figures. These facts
are advantages of the MSCSA technique, because they allow
that the detection and diagnosis of fault are more accurate.
However, for the inter-turn short, the application of the two
techniques showed with equivalent capabilities to diagnose the

78
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