A Review of Condition Monitoring of Induction
Motors Based on Stray Flux
Chen Jiang1, Sufei Li1, and Thomas G. Habetler2
1
School of Electrical and Computer Engineering
Georgia Institute of Technology
Atlanta, GA 30332, USA
{cjiang41, sli314}@gatech.edu
Abstract—The induction motors are widely used in different
industry areas which can experience various kinds of faults in
stators and rotors. In order to early diagnose motor faults, the
classical condition monitoring method focusing on stator current
spectrum is well researched and presented. There are already
some review papers related to traditional current monitoring
method. However, when it comes to the stray flux detection, almost
no researchers did a general review on this topic. This paper
mainly presents the review of stray flux detection of induction
machine. The development and application of stray flux detection
method are detailed presented. Comparison with stator current
detection is presented aiming at stator insulation failure, bearing
fault, eccentricity and broken rotor bar/end-ring. Although stray
flux method is used mostly for induction machine, its potential
application in PMSM will be included as well.
Keywords—Inducion motors; stray flux; condition monitoring;
PMSM.
I. INTRODUCTION
Condition monitoring has increased importance in rotating
electrical machines. There are many proposed methods to
monitor electric machines, which some of them are
commercially employed in the condition monitoring. In
addition to insure a high degree of uptime reliability, the
condition monitoring techniques are designed to pursue
efficiency, safety, and performance of the electrical machines
[1]. Mechanical vibrations levels, temperature, harmonic
content of the stator current and voltage, and different fluxes
are several proposed parameters by which one can monitor
electrical machine condition.
According to the past research, the main causes of electrical
machines failure include [2]:
1- Design and manufacture defects
2- Improper ambient conditions
3- Overload and over-speed
4- Fatigue
The root causes mentioned above may appear in a machine as:
1- Stator insulation failure
2- Bearing fault
3- Broken rotor bar/end-ring detection
4- Air gap eccentricity
978-1-5090-2998-3/17/$31.00 ©2017 IEEE 5424
2
Fellow, IEEE
Georgia Institute of Technology
Atlanta, GA 30332, USA
tom.habetler@ece.gatech.edu
Failure surveys have reported that the percentage of failure
by components in induction machines is typically: bearing
related (40 %), stator related (38 %), rotor related (10%), and
others (12 %) [3].
When some faults mentioned above happen to an induction
machine, a portion of the magnetic flux will radiate outside of
the machine’s frame because of the inherent machine
dissymmetry, the limited relative permeability of the magnetic
circuit, and the effects of the air-gap length. While stray flux
component does not participate in the process of generating
useful outputs (voltage and torque), it can be utilized to monitor
the machine condition [4]. In the past years, stray flux detection
has been widely researched and implemented in some areas
such as railway construction and monitoring. In addition, some
researches focus on the health issue of stray flux emission
providing a safety region for humans in the vicinity of motors,
although the measured signal is very weak and could easily be
affected by the surrounding noises [5]. Some other early
research shows that large power electrical machine is a
significant source of magnetic emission in the lower frequency
range up to nearly some MHz [6]. Actually, the stray flux value
should be correlated with the machine operating conditions (full
load, half load, no load, full speed, half speed, short circuit).
For induction machines specifically, stray flux is induced by
stator and rotor currents, but the effect of stator currents
prevails, since the stator acts as a magnetic shield with respect
to the rotor [7]. Compared to the current detection methods,
sensing flux can avoid the problem because flux sensors may
be set outside the body of any electrical machine and they give
almost the same final information as the current sensors do.
However, the level of the fault component magnitude is lower
than the same one of the current spectra. This is obvious
because the sensor is outside the machine and all the
phenomena are filtered and smoothed [8], [9].
II. EXTERNAL MAGNETIC FIELD ANALYSIS
Methods based on the analysis of external magnetic field
have been developed in the 70’s by Penman [10]. The drawback
of these methods is tied to the difficulty for modeling the
magnetic field that strongly depends on the electromagnetic
behavior of the stator yoke and of the motor housing, which
have an important shielding effect [11]. Some approaches need
simple geometries [12]-[15] but these methods, based on
simplified geometry and under particular hypotheses, can be
hardly exploited for electrical machines. The external magnetic
field can be studied by the mean of the axial and radial
decomposition according to most of the papers.
Reference [16] does some research from the theoretical
point of view, 2D and 3D FEM have been made, the difficulty
being in the magnitude difference of the magnetic field between
the inside and the outside of the machine. Nevertheless, with a
proper geometric representation, the stray fields have been
obtained with an acceptable accuracy. This encouraging result
will allow the design of electromagnetic shields around the
machine. Another paper proposes two approaches to compute
the magnetic stray field created by faulty electrical machine.
First one is based on the homogenized FEM method. The
second one is based on combination of an analytical expression
for the magnetic field in the air gap with an integral method.
Both methods can save significantly CPU time and memory
[17]. Reference [18] also present a theoretical approach of the
stray flux analysis in a three-phase squirrel-cage induction
machine for stator and rotor electrical faults detection. The stray
flux is analyzed in a point outside the machine using the Biot-
Savart law, taking into account the effect of the end-windings
for the stator and the end-ring segments for the rotor squirrel-
cage.
In [19], Kokko states that the determination of the complex 3D
pattern of this stray flux is difficult but not necessary. When it
comes to the threshold setting, since the condition monitoring
of motors by axial flux is based on the relative changes in
certain flux frequency components, their absolute amplitude
values are not required [7]. Recently some researchers also
present FEM followed by Neuro Fuzzy Logic method to
statistically analyze different kinds of motor faults [20], [21].
III. DEVELOPMENT OF STRAY FLUX DETECTION
INSTRUMENTS
The magnetic leakage flux is straightforwardly measured by
circular search coils, which are placed on the rear end of the
machine concentric with the shaft. These coils generate a
voltage proportional to the rate of change of the leakage flux
[2]. In addition to search coils and hall sensors, some other
sensors such as optical fiber and radio frequency sensors are
utilized for monitoring of electrical machine [22], [23]. An
integrated fluxgate sensor is implemented to detect the magnet
defect faults [24]. In recent years, researchers develop new
magnetic flux detection devices to increase sensitivity and
accuracy of condition monitoring systems. A "C-shape" flux
probe is developed in, which can be installed for different
machine sizes. Nonetheless, these search coils are based on
5425
Faraday's Law of Induction and cannot measure static magnetic
field [25]. Other instruments such as GMR (Giant
Magnetoresistance) sensors make static flux and point
measurements possible and are extremely useful for condition
monitoring. The GMR sensor is based on the GMR effect which
is a significant change of the electrical resistance depending on
whether the magnetization of adjacent ferromagnetic layers are
in a parallel or an antiparallel alignment. They have very high
resolution and sensitivity. GMR sensors have been applied to
nondestructive testing and evaluation for ferromagnetic or
electrical conductive materials. They have proven advantages
of high sensitivity and spatial resolution, linearity and
frequency responses to magnetic fields [26], [27]. They have
already been applied for inspection of different depth and
orientation of the crack in plates, bearings and rails.
IV. STATOR INSULATION MONITORING AND FAILURE
DETECTION
In the field, winding failures are a major fault accounting
for over 45% of total machine failures. In the literature, many
condition monitoring techniques based on different failure
mechanisms and fault indicators have been developed where
the machine current signature analysis is a very popular and
effective method at this stage. However, it is extremely difficult
to distinguish different types of failures and hard to obtain local
information if a non-intrusive method is adopted. Typically,
some sensors need to be installed inside the machines for
collecting key information, which leads to disruption to the
machine operation and additional costs.
Some publications have been established using stray flux to
detect the stator winding insulation failure. The main
differences are sensor type, sensor direction and sensor
quantity. The FEM is the basic method to build 2D or 3D
machine model together with some statistical analysis.
Reference [26] presents a new non-invasive monitoring method
based on GMRs to measure stray flux leaked from the
machines. It is focused on the influence of potential winding
failures on the stray magnetic flux in induction machines. Finite
element analysis and experimental tests on a 1.5-kW machine
are presented to validate the proposed method. With time-
frequency spectrogram analysis, it is proven to be effective to
detect several winding faults by referencing stray flux
information. The novelty lies in the implement of GMR sensing
and analysis of machine faults. Some other novelties are
introduced by using different flux probes in different positions
around the machine and the statistical evaluation of the
experimental results [28]. This analysis has revealed an
important variation of some harmonic components, especially
in the axial body flux collected by the sensor designed and
constructed in laboratory. The tests in load and no-load
conditions have shown significant similarities, even if the stator
current gives interesting diagnostic information only when the
motor is loaded: so, especially at no-load, the stray flux seems
more efficient for this fault diagnosis. In addition, an increased
efficiency of the fault detection and the possibility to detect the
azimuth position of the short-circuit fault inside the stator are
offered by a system of two coil sensors series connected, one
pole shifted around the motor [29]. Considering power supply
harmonics, it is possible to easily detect the stator winding
faults in the low-frequency range of the flux spectrum with low-
frequency resolution [30].
V. BEARING FAULT DETECTION
Percentage rate of bearing faults is approximately 35%-55%
from all causes of machine failure [31]-[33]. Some authors have
presented even much higher percentage of bearing faults, e.g.
Immovilli [34] up to 90% for small machines. Therefore,
bearing faults are often investigated issue in the field of electric
machines diagnosis [35]. Approximately 40% of bearing
premature fails are caused by inadequate or improperly used
lubricants [36]. Most common indicators for potential bearing
problems are the increased temperature and high vibration or
noise level of the machine [37].
Two types of bearing faults are usually distinguished. The
first are single point defects and the second is generalized
roughness. In case of single point defects, the characteristic
spectral components in vibration signal can be predicted for
inner ring, outer ring, rolling element and cage fault. These
frequencies can also appear in stator current around the
fundamental harmonic [38]. Although they are usually clearly
visible using vibration analysis, in case of stator current it is
difficult to observe them due to their low amplitude and noise
disturbance [34]. Regarding this, the number of signal
processing method has been applied, but the results are still not
clear. In contrary to single point defects, generalized roughness
does not produce characteristic frequency, but rather specific
frequency bands.
Stray flux based bearing fault diagnosis method was
implemented in several papers, most of which use several
search coils and flux probes. Some experimental measurements
were carried out by means of a current probe and by means of
different flux probes, positioned in different positions [7], [39].
The comparison is conducted to find the main advantages which
are the simplicity and the flexibility of the custom flux probe
with its amplification and filtering stage. The flux probe can be
easily positioned on the machines and adapted to a wide range
of power levels. Industrial probe such as Emerson (M-343F-
1204type) is implemented in [7], which has several turns wound
around a circular air core. This probe has to be mounted on the
fan end of the machine and can be used to measure only the
leakage axial flux. Other custom flux probes like the one
consisting of a semicircular ferrite core with 44 mm outer and
40 mm inner diameters are utilized to detect the winding fault.
The main advantages of this cheap (of only about a few Euros)
flux probe over the industrial ones is its small size, which
5426
enables the measurement of the stray flux anywhere around the
machine [7].
VI. AIR GAP ECCENTRICITY DETECTION
Generally, the eccentricity of up to 10% is permissible and
it should not have significant influence on motor characteristics
and lifetime [40], [41]. However, the higher level of
eccentricity gives rise to unbalanced magnetic pull (UMP) and
therefore noise, vibration and excessive bearing wear occur [6],
[20], [42].
For machines' monitoring purpose, the classical motor
current signature analysis has shown its weakness in
distinguishing the eccentricity occurrence in presence of others
mechanical faults. Although Park's vector approach can cover
this drawback, the high cost due to the requirement to use three
current sensors associated with an advanced processing
technique, makes it less desired by industrialists. Moreover,
detection of dynamic eccentricity in stator current around the
principal slot harmonic (PSH) is effective only for some
combination of number of pole pairs and rotor slots [43].
The experimental results have revealed the potential of a
simple search coil for the detection and the distinction of the
accurate eccentricity nature even in presence of similar
mechanical faults [44]. Dynamic eccentricity produces low
frequency air gap flux components, however, they can be
observed in stator current only under mixed eccentricity. Unlike
MCSA (motor current signature analysis), stray flux detection
method allows to detect purely dynamic eccentricity or to detect
dynamic eccentricity under mixed eccentricity with a minimal
effect of static eccentricity [45]. This feature can be understood
as an advantage of this method, because the same frequency
components f1 ± fr are presented in stator current only if both
types of eccentricity exist together and it is not easy to
distinguish them. Drawback of the method is relatively
significant impact of the stator yoke saturation [45], [46]. Most
of the papers related to this part pay attention to measured
motors with static, dynamic and mixed eccentricities, as well as
the healthy one. Measurements were carried out for four types
of loads: no load, half-load, full load and overload [47].
VII. BROKEN ROTOR BAR/END-RING DETECTION
Induction motors are widely used in industrial applications,
and among the defects which may appear, broken rotor bars
represent 10% to 20% of the whole faults. This kind of failure
does not cause immediate break down, but deteriorates the
operation of the machine, decreasing its performances [48]-
[51].
Each method has its advantages and disadvantages, but it is
essential that the used method should be able to detect incipient
faults and to prevent the total damage (unexpected shutdowns).
Reference [52] presents a new approach to detect broken bars
fault in squirrel-cage induction machine. This approach is based
on the study of stray flux signal after the supply disconnection.
This type of test is useful especially for the maintenance
purpose when it is possible to remove the load and supply
effects. After supply disconnection, only the rotor current
effect can be captured. In this case, the current in rotor side
decrease by its time constant and the spectrum induced in a
search coil around the induction machine is analyzed with a
time-frequency method allowing the rotor faults detection. The
broken rotor bar effect is analyzed in the induced stator voltage
spectrum too, but the experimental results show that its
sensitivity is weak with respect to the given by the search coil
induced voltage spectrum. Reference [48] presents a new
signature of rotor faults in induction machines. This signature
concerns the external magnetic field, particularly the axial
components, measured by a simple coil sensor and the analysis
is oriented to the low frequency components of the FFT
spectrum at sf and 3sf. The description of component sf is done
by the permeance circuit model that considers the permeances
related to axial fluxes on the machine extremities. The
advantage of this noninvasive method compared to other
existing methods is its simplicity to implement and a low cost
set-up. Also, it does not require the knowledge of the healthy
signature, and it is weakly influenced by the magnetic shield of
machine frame because the observed phenomena are in very
low frequency. Moreover, the frequencies of the observed
components depend on the machine running (the slip);
consequently, the analysis is not disturbed by other sources of
magnetic field presented in an industrial environment.
Specific sensor type, sensor direction under different faulty
conditions based on some typical stray flux detection of
induction motor is given in Table I.
VIII. CONCLUESION
Above all, one of the advantage of stray flux detection is its
non-invasive measurement. Besides, comparing with the
winding current signature analysis which under some
circumstances cannot discriminate between different faults
such as eccentricity, stray flux analysis is much more sensitive,
robust and reliable, thus is suited for initial fault detection for
induction machine. Moreover, its results include rich
information such as the location of defects in induction
machine.
However, the main limitation of using flux sensors is that it
is difficult to access to the target motors. Sometimes, the sensor
is put with a distance away to the motor which decreases the
accuracy of the experiment results. In addition, placing the
external flux sensor leads to greater difficulties in the
repeatability, for the purpose of monitoring, taking into account
that the diagnosis is always carried out from a reference signal
which considers the machine running under appropriate
conditions. Thus, for an efficient diagnostic it is necessary to
5427
always attach the magnetic flux sensor in the same position.
Besides, the threshold values of these axial flux harmonics,
which can distinguish a faulty motor from a healthy motor, are
not easy to predetermine, because several factors affect them
especially the sensor location and motor model. For this reason,
it is recommendable to collect a reference measurement of the
flux for each healthy motor, to find out experimentally the
relative distribution of these harmonic components. Moreover,
the result of the stator current analysis cannot be directly used
as a reference value for axial fluxes. The stator current spectra
are quite alike for similar motors; hence, the spectrum of one
motor can be quite reliably used as a reference value for another
similar motor. In the axial flux spectra, there are so many
differences among the various motors that it is better to set a
reference measurement for each machine.
Flux analysis is used mostly for induction motors, hence for
PM synchronous motor faults regarding the permanent magnet
as a flux source, the stray magnetic field from the motor can be
included in the magnetic circuit of the motor. It is shown that
mesh and its related frequencies which cannot be easily
identified in stator current show up in the EMF stray flux
spectrum. And stray flux detection will be widely exploited to
diagnose other faults in PMSM.
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 Table IˊSpecific sensor type, sensor direction under different faulty conditions

Reference Sensor Type Flux Direction Sensor Feature

Inexpensive, wide
frequency response
can help identify
26 Giant magnetoresistive (GMR) sensors radial
different types of
winding failures in
induction machines.
Stator Insulation Failure
˄1˅ hand-made flux probe˄ferrite core,
˄1˅radial and The commercial
300 turns of enamelled copper of diameter
28 axial sensor (2)
0.112 mm˅
˄2˅axial is widely used
˄2˅Emerson M-343F-1204 (air-core)
Hand-made flux sensor (air core, several
30 Cheap
hundred turns)
The main advantages
(1)Industrial probe such as Emerson (M-343F-
of (2):
1204type)
7 (1) axial 1.only about a few
Bearing Fault (2)The core is wound with 300 turns of
Euros
enameled copper of 0.112 mm indiameter.
2.smaller size
45 Small active area sensor tangential
44 Low cost sensor(simple search coil) axial and transversal
45 Hall probe active area sensor tangential
Airgap Eccentricity F.W. Bell 7030 Gauss/Teslameter and the
47 magnetic
flux sensor
External coil sensor, manufactured in the
laboratory, area (S=12 cm2) and n turns (n =
48 axial and radial
Broken Rotor Bar/End Ring 1200)
.
49 Search coil

5430