Faults diagnosis for electrical machines based on
analysis of motor current
Mariana IORGULESCU, Robert BELOIU
University of Pitesti, Electrical Engineering Departament
iorgulescumariana@mail.com
Abstract -This paper introduce faults diagnosis based on
current analysis. The current spectrum of a three phases and
single phase induction motor and also of a DC motor, are
analyzed in order to achieve information for the detection of
different faults. In order to perform the diagnosis we analyzed
signals of current from the ampere sensor. The Fast Fourier
Transform is applied to the signals acquired. We observe
significant current spectrum differences between healthy motors
and motors with faults. The high-frequency spectral analysis of
current provides a method to detect bearing faults, broken rotor
bars faults and commutator short circuit and presence of a
displaced permanent magnet out of poles in polar axe.
The system developed is scalable to different power ratings
and it has been successfully tested with data from 0.75kW three
phases induction motor, 0.65kW single phase induction motor
and DC motor with permanent magnet.
I. INTRODUCTION
Electrical machines are presents in almost all branches of
industry. In last years and in the context of increasing
competition there is a greater demand for modern industrial
systems to become safer and more reliable. Process failure
can potentially result not only in the loss of productivity but
also in the loss of equipments and human lives. This is why
there is a growing need for the development of procedures
used for faults detection and diagnosis in order to increase
reliability and the availability of the installations. Also, early
detection and diagnosis of faults can help to avoid equipment
breakdown and material damage.
The three phase induction motors, particularly the squirrel
cage type are frequently used because of their relative
simplicity, robust construction and low price. Induction
motors are known as highly reliable. However these types of
motors can come under external and internal stresses, which
can result in degradation of their electrical or mechanical
parts. It is well known that the bearing faults constitute a
significant part of the faults of the induction motors. So, it is
necessary to detect these faulty conditions in an incipient
stage and prevent them from developing before they can
result in huge failures for electrical equipments.
Single phase induction motors are used for a wide range of
activities, industrial application and domestic appliances. In
industrial application of single phase electric motors it is
well-known that the interruption of the fabrication process
leads to financial loss. Also in the utilisation of domestic
appliances, the breakdown of the electric motor induces
financial loses too, because it affects the reputation of the
brand. Thus companies which produce domestic appliances
should request from the manufacturers of the electric motors a
978-1-4799-5183-3/14/$31.00 ' 2014 IEEE 291
higher quality of their products. In consequence, the electric
motor manufacturers should use diagnosis systems that can
detect motor’s faults. In induction motors, function
interruption can be caused by bearing faults, stator faults,
rotor faults - broken rotor bars or rotor end ring and rotor –
stator eccentricity. Broken rotor bars rarely cause immediate
failure. But, if there are enough broken rotor bars, the motor
may not be able to develop sufficient accelerating torque.
Low power DC motors with permanent magnet are widely
used in automotive industry. The control of DC motors is
relatively simple and they are suitable for a wide range of
operating conditions. DC motors are used in industrial
systems, such as robotic manipulators. Considering that, the
faults diagnosis and quality control for DC motors have
received growing from engineers. [1]
Most of the faults of DC motors are regarding
commutator’s motor, short circuit of the commutator and
presence of a displaced permanent magnet out of poles in
polar axe.
Many have researchers have worked to develop methods
for faults diagnosis. In some of these approaches fast Fourier
Transform is used to examine the presence of faults in the
process and give a fault signal classification and to declare
whether the process is faulty or not.
In the present work, we propose to study this problem. The
results of diagnosis obtained on three phase, single phase
induction motors and DC motor based on current analysis are
presented.
II. FAULTS OF ELECTRICAL MOTORS
II..1 BROKEN ROTOR BARS AND BEARINGS FAULT IN
INDUCTION MOTORS
The main faults of induction motors can be classified as
following:
• Bearing wear and failure. As a result of bearing wear, air
gap eccentricity can increase, and this can generate serious
stator core damage and even destroy the winding of the stator;
• Stator faults resulting in the opening or shorting of one or
more of a stator phase windings,
• Abnormal connection of the stator windings,
• Static and/or dynamic air-gap irregularities
• High mechanical unbalance in the rotor increases
centrifugal forces on the rotor;
• Broken rotor bar or cracked rotor end rings
 • Looseness or decreased stiffness in the bearing pedestals
can increase the forces on the rotor;
• Critical speed shaft resonance increases forces and
vibration on the rotor core.
• Bent shaft which can result in a rub between the rotor and
stator, causing serious damage to stator core and windings
[2], [3], [4], [5], [6].
The three phase induction motor stator current is measured
to detect bearing faults and in the single phase case the fault
detects is a broken bars rotor.
II..2 DC MOTOR FAULTS
Faults might intervene in the functioning of DC machines
both when starting to function or after a long time of
functioning. The faults could be electric or mechanic.
Electric nature faults are:
• Problems with driven equipment
• Improperly set neutral kick
• Cracked commutator risers
• Open circuited armature coil
• Wrong functioning control circuit
• Inaccurately connected fields
• Grounded armature circuit
• Grounded field circuit
• Control instability
Mechanical faults are:
• Bearing support heating
• Machine’s vibrations.
DC electrical machines are easy to control but the
functioning analysis of them is very complex from theoretical
point of view.
Some of these DC motors problems are the following:
• In overloading case the motor’s current is bigger than
rated value. This physical phenomena leads to sparking at the
brushes and commutator run out, also. These kinds of faults
appear because of wrong position for brushes or wrong
connection of commutation poles.
• When the power supply of electric motor turn out over
voltage the temperature inside motor will increase. The same
results it is when wrong succession of the poles. We have in
this case the overheating of the electric motors and the shaft
speed higher than nominal. In these cases near the
overheating appear commutator’s sparks.
• In generally for induce reaction decrease brushes will be
displacement off neutral axe. This acts leads to demagnetizing
effect.
• It is known that magnetic saturation effects cause non-
linear relationships between volts and amps. Mathematical
analysis methods generally make the assumption of linearity.
Motor functioning depends on magnetic flux to produce
voltage and torque, so they need as much flux as possible. In
this case the motor operate near the knee of the magnetization
curve (flux not linearly related to the electromotive force).
This non-linearity as a result gives peculiar behaviours to
machines.
292
• Sometimes DC motor drives have feedback control,
with feed back signals coming from armature current, current
limit, field current, process variables, etc. If control instability
happened, amplitude modulation of the applied voltage can
result, even when driving very stable loads.
These above incidents that could be in motor can lead to
the consequences for motor’s performance, such us:
• sparks at the commutator,
• overheating of the motor,
• abnormal starting,
• abnormal speed,
• low possibilities of load the motor.
Developing of the abnormal speed appears after the
machine started correctly. This fault could occur because of
misplacement of the poles on the collector, they could be
outside of neutral area. On the other side the speed could
oscillate because the brushes are behind the neutral axis.
Regarding these reasons, in the practical world,
mathematical analysis of DC machines becomes less
important than practical measurements and practical
understanding. Therefore we need to take reliable
measurements on DC machines to determine if they are
working correctly – and if they are not, to point us in the
direction that will get them work correctly. [8],[9]
The DC machines current are measured by ampere sensor
to detect DC motor’s faults.
III. CURRENT SPECTRUM MONITORING
The techniques used to detect the presence of rotor cage
failure and bearings fault are:
Spectrum analysis of machine stator current (MCSA) to
detect broken bar faults. We investigate the sideband
components, f b, around the fundamental one in order to
detect broken bars faults.
f b = (1 ± 2s ) f (1)
where f is mains frequency, s is the motor slip
While the lower sideband is specifically due to broken bar,
the upper sideband is due to consequent speed oscillation. In
fact it shows that broken bars actually give rise to a sequence
of such sidebands given by:
f b = (1 ± 2ks) f , (2)
where f is mains frequency, s is the motor slip and k =
1,2,3,…..
The motor-load inertia also affects the magnitude of these
sidebands. Other spectral components that can be observed in
the stator current are given by:
f = [(k / p)( 1 − s) ± s]f (3)
b
where, f b = detectable broken bar frequencies; f is mains
frequency, s is the motor slip and k/p = 1,3,5... [10],[11],[12]
The analysis of stator current spectrum is used for the
detection of bearing faults. The faults detection will be done
by comparing two values: the amplitudes of the harmonic
components obtained from monitoring the current spectrum at
different frequencies and the amplitudes of the harmonic
components at the same frequencies obtained from the
reference spectrum.
It has shown that these frequencies reflect themselves in
the current spectrum as:
f br = f 1 ± kf ν (4)
Where: k = 1,2,3,… and fv is one of the characteristic
current frequencies.[13],14],[15],[16],[17],[18]
A physical explanation for this phenomenon is that the
rotor’s machine lay in the bearings, and a minor faults of
them leads to a radial movements between stator and rotor of
the motor. The air gap variation generated oscillation of
motor’s inductances, leads in facts to modulations of stator
currents.
For example, if there are a erosions of path way of bearing
the ball of this fall down and have been radial movement. So,
the air gap geometry will be modified and in the same mode Fig.1 Measurement equipment
the stator current will be affected.
The stator currents modifications appear at the frequencies IV.1 SINGLE PHASE INDUCTION MOTOR STATOR
settled in the above relations. CURRENT SPECTRUM MONITORING
The frequencies corresponding to faults bearings are
calculated using the formulas (1),(2),(3),(4). The current analysis is very useful for single phase
Must be noted, that the stator current spectrum will be induction motor manufactures in order to diagnose broken
contain also the other components of frequencies. These will rotor bars faults.[19]
be given by the saturation phenomen, stator winding Figure 2 presents the rotor of single phase induction motor
repartition on the stator geometry, and so on. used in experiment.
The components corresponding for bearing faults are
different from these frequencies.
These techique of detection’s bearing faults is very useful.

IV. ELECTRICAL MOTORS DIAGNOSTICS BY

CURRENT SPECTRUM
The current signal is received by the ampere clamp. It is
necessary to analyze this signal without losing the diagnostic
information. There are very strict requirements for the
analyzing instruments. The operations that the current
analyzing instruments must perform are the following:
• Measurement of overall current level in a standard
frequency range and using the units required by these
standards.
• Spectral analysis of the current, by using FFT. Fig.2 Rotor with squirrel cage for single phase induction motor
Harmonic spectra are generated from collected data by the
ampere clamp using FFT. In figures 3, 4 we present the harmonic stator current
The Fourier fast transform (FFT) is a mathematical spectrums for the induction motor with “healthy” rotor and
operation that is used to extract from a time-domain signal the faulty rotor bars.
frequency domain signal representation In figure 5 we present a comparative analysis of the
The analysis of the spectrum of random high frequency harmonic stator current spectrums for the induction motor
current signal is usually used. with “healthy” rotor and the ones with broken bars (from one
Experimental methods focus on current diagnosis. The to three broken bars).
tested methods are according to standard procedure of product
and measurement’s sizes. A specialised system was used for
measure vibrations and currents with regard to electric
machines diagnosis. The measurement was made in studies
vibration laboratory used also for currents analysis. This
equipment is presents in figure 1.

293
 Comparison betw een currents spectrum
stator current harmonic components at 50,100, 250Hz as in
figures 6, 7and 8.
0.001000000
Comparison current spectrum 50 Hz
10 100 1000 10000

0.0002000000
0.000100000
0.0001800000

0.0001600000
0.000010000
0.0001400000

0.0001200000

current A / uV
0.000001000

0.0001000000

0.000000100 0.0000800000

0.0000600000

0.000000010 0.0000400000

0.0000200000

0.000000001
0.0000000000
f r e que nc y [ H z ] 45 46 47 48 49 50 51 52 53 54 55
frequency [Hz]

"healt h"rot or 12p rot 2B 12p rrot N 12p rot 3B 12p rot 1B

Fig.3 Harmonic stator current spectrums for “healthy” motor Figure 6 Comparison between stator current spectrum “healthy” and rotor
bars fault at 50Hz
Com parison betw een currents spectrum
Comparison current spectrum 100 Hz

0.001000000
0.0000010000
10 100 1000 10000

0.0000009000
0.000100000

0.0000008000
0.000010000
0.0000007000

0.000001000 0.0000006000
current [A / uV]

0.0000005000
0.000000100

0.0000004000

0.000000010
0.0000003000

0.0000002000
0.000000001

f r e que nc y [ H z ]
0.0000001000

one broken bar "healt h"rot or

0.0000000000
90 92 94 96 98 100 102 104 106 108 110
frequency [Hz]
Fig4. Comparison between harmonic stator current spectrums for “healthy” 12p rot 3B 12p rot N 12p rot 2B 12p rot 1B
and one rotor bars broken
Figure 7 Comparison between stator current spectrum “healthy” and rotor
bars fault at 100Hz frequency
Comparison betw een currents spectrum
Comparison current spectrum 250Hz

0.0000100000
0.001000000
10 100 1000 10000 0.0000090000

0.0000080000
0.000100000
0.0000070000

0.0000060000
current A / uV

0.000010000
0.0000050000

0.0000040000
0.000001000
0.0000030000

0.0000020000
0.000000100
0.0000010000

0.0000000000
240 242 244 246 248 250 252 254 256 258 260
0.000000010
frequency [Hz]

12p rot N 12p rrot 2B 12p rot 1B 12p rot 3B

0.000000001

f r e que nc y [ H z ]

Figure 8 Comparison between stator current spectrum “healthy” and rotor

one broken bar t wo broken bars
Fig.5 Comparison between harmonic stator current spectrums for “healthy”
and fault rotor bars
Comparing those three spectra we see a small difference
but not very visible at this scale.
So, is important to make a zoom of each domain of
frequency.
The amplitudes of the stator current harmonic components
for the induction motors being tested have been calculated
according equations (1),(2) and (3). We also analyze the
t hree broken bars "healt h"rot or
bars fault at 250Hz frequency
We observe for a frequency around ±20Hz the mains
frequency the amplitude current stator it is bigger with 5%
than that for the same motor without rotor fault.[20]
A diagnostic procedure using a neural network shall be
designed to detect any fault which may come out.
It is demonstrated that the method of stator current
signature is very efficient for single induction motor
diagnosis, stator faults, rotor faults (in this case rotor broken
bars).

294
 Comparison between current spectrum 150 Hz
IV.2 THREE PHASE INDUCTION MOTOR STATOR
CURRENT SPECTRUM MONITORING 0.000400
0.000350

s ta to r c u r r e n t [A / u V ]
Stator current spectrum analysis is very useful to detect 0.000300
motor"healtly
bearing faults. 0.000250
motor with incipient fault
At the beginning we make a scratch on the rolling path and 0.000200
bearing
realize an acquisition of current signal. We consider this to be 0.000150
motor with advance on fault
0.000100
the incipient fault. After that we make a deep scratch of the bearing
0.000050
rolling path and we consider this to be the advanced bearing 0.000000
fault and also take a current signal. 145 147 149 151 153 155
In Figures 9 and 10 present the comparison between frequency [Hz]
harmonic stator current spectrums for motor without fault and
with incipient bearing fault and with advanced fault. Fig.11 Comparison between stator current spectrum “healthy” and bearing
fault at 150Hz frequency
Comparison between current spectrum

0.01000
Comparison between current spectrum 175 Hz

0.000030
0.00100

s ta to r c u r r e n t [A / u V ]
0.000025 motor"healtly
Current [A/uV]

0.000020
0.00010
motor with incipient fault
0.000015
bearing
0.000010 motor with advance on fault
0.00001
0.000005 bearing

0.000000
0.00000
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 170 172 174 176 178 180
Frecventa [Hz]
frequency [Hz]
no fault motor fault bearing

Fig.12 Comparison between stator current spectrum “healthy” and bearing

Fig. 9. Comparison between harmonic stator current spectrums for “healthy” fault at 175 Hz frequency
motor and incipient bearing fault
We notice that the amplitudes of frequencies are related to
fault bearing. For the incipient fault we found a 5% increase
Comparison between current spectrum
of the current amplitude at 50Hz, followed by an increase at
20% for advanced bearing fault.
0.100000 This technique for bearing faults diagnosis could be used
10 100 1000
0.010000 with success by experts. Using the artificial intelligence the
stato r cu rren t [A/u V ]

motor"healtly
0.001000 research can be focused on the frequencies in concordance
0.000100
motor with incipient fault with equation (4). In the case of increase amplitude the
bearing
0.000010 motor with advance on fault
conclusion is that the motor bearing has failures.[21],[ 22]
bearing The method of signature motor current analysis is very
0.000001
efficient in bearing faults detection and rotor broken bars.
0.000000
It is important to mention that the mechanical faults
frequency [Hz]
together with electrical faults can be detect by the stator
current monitoring, an electrical parameter. [23]
Fig. 10 Comparison between harmonic stator current spectrums for “healthy”
motor and bearing fault
IV.3 DC MOTOR CURRENT SIGNATURE
In the same mode like for the single phase motor
comparing those three spectra we see a small difference but The current analysis is very useful for DC manufactures in
not very visible at this scale. It is necessary a sufficient faults diagnosis
resolution that can be observe easily the characteristics In figures 13,14,15,16 we present the harmonic current
frequencies of the bearing fault. spectrums for the DC motor “healthy” and with different
The amplitudes of the stator current harmonic components fault.
for the three phase induction motors being tested have been
calculated according equation (4).
We analyze the stator current harmonic components at 150
and 175Hz as in figures 11 and 12.

295
 Current spectrum of "healthy" DC motor Current spectrum of DC motor

3.50
1.40
3.00
1.20 2.50

c u rre n t [A ]
1.00 2.00 DC motor with permanent
c u r r e n t [A ]

magnet 25 degree placed out of

0.80 1.50 pole axis
1.00
0.60
0.50
0.40
0.00
0.20 0.00 1000.00 2000.00 3000.00 4000.00 5000.00
0.00 speed [rpm]
0.0 500.0 1000.0 1500.0 2000.0 2500.0 3000.0 3500.0 4000.0 4500.0 5000.0
speed [rpm] Fig. 16. Current spectrum for DC motor with permanent magnet displaced 25
degree out pole of axis

Fig. 13. Current spectrum for DC motor without fault In figure 17 and we present the DC current spectrums
comparative analysis for DC motor “healthy” and with
DC motor with permanet magnet placed out of pole axis different faults.
comparation of DC motor current
7.00
10.00 DC motor "healty"
6.00 9.00
8.00

D C m o to r c u rre n t (A )
5.00
c u r r e n t [A ]

7.00 DC motor w ith

permanet magnet
4.00 6.00 placed out of pole axis

3.00 DC motor with permanet 5.00 DC motor w ith

magnet placed out of pole 4.00 permanent magnet
dispaced 25 degree
2.00 axis 3.00 betw een neutral axe

2.00 DC motor w ith short

1.00 circuit of tw o
1.00 commutator bars

0.00 0.00
0 1000 2000 3000 4000 5000
0.0 1000.0 2000.0 3000.0 4000.0 5000.0
speed (rpm)
speed [rpm]

Fig. 17. Comparison between current spectra for DC motor “healthy” and
Fig. 14. Current spectrum for DC motor with permanent magnet placed out of with faults
pole axis
For the relevant conclusions we need to make a zoom in for
the speed range 500-2000 rpm. So we obtain the comparison
Current spectrum of DC motor
in figure 18.
We observe that in the speed range 500-2000 rpm the
10.00 amplitude current beginning with DC motor with permanent
8.00 magnet placed out of pole axe and finally with the bigger
amplitude for the DC motor with short circuit to commutator
c u rre n t [A ]

6.00
DC motor with shortcircuit of
two commutator bars
bars.[24]
4.00

2.00
comparation of DC motor current
0.00
0.00 1000.00 2000.00 3000.00 4000.00 5000.00 4.00 DC motor "healty"

speed [rpm] 3.50

D C m o to r c u rre n t (A )

3.00 DC motor w ith

permanet magnet
2.50 placed out of pole axis
Fig. 15. Current spectrum for DC motor with short-circuit to commutator
2.00 DC motor w ith
permanent magnet
1.50 dispaced 25 degree
betw een neutral axe
1.00 DC motor w ith short
circuit of tw o
0.50 commutator bars

0.00
500 700 900 1100 1300 1500 1700 1900
speed (rpm)

Fig. 18. Comparison between current spectra for DC motor “healthy” and
with faults for speed range 500-2000 rpm

296
 It is demonstrated that the method of DC motor current
signature is very efficient to make DC motor diagnosis,
Also, it is known the fact that the short circuit to
commutator provoked damage of the DC motor. Using the
current signature these kinds of faults can be detect in the
incipient stage.
V. CONCLUSIONS
The technique of evaluating the electrical equipment
condition by performing a FFT of DC motor and induction
motor current spectrum has been verified by the experimental
results. In this case electric motor’s currents motorizing is
very useful to detect short-circuit between in the collector of
dc motor, or bearing fault, or broken rotor bars of single
induction motor.
By the corresponding zoom we can observe that currents it
is different at the “healthy” electrical motors related fault
motor.
For a correct diagnosis for each of motor we need to study
the current amplitude corresponding to frequencies equal with
multiples of main frequency.
Thanks to these methods the diagnosis of different faults of
electrical machines can be detected even if the electrical
motors are unloaded.
It is demonstrated that the method of current signature is
very efficient to make electrical motors diagnosis even is DC
or AC motor.
In this way, the production equipments maintenance can
easily and successfully detect mechanical and electrical fault
that lead to unexpected downtime.
A diagnostic procedure using a neuro-fuzzy system shall be
designed to detect any fault may come out.
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