Computer Aided Online Fault Diagnosis of Induction Motors

Suri Sathya Prashant

Final Year BTech EEE Department GNEC; JNT University Hyderabad, India

S.Shyam Sunder
Final Year BTech EEE Department GNEC; JNT University Hyderabad, India

K.SatyaKrishna
Pre Final Year BTech EEE Department GNEC; JNT University Hyderabad, India

S.A.Sharma
Retd.Area Manager ALSTOM Hyderabad, India

Abstract- 75%of the electrical energy generated in India is utilized for running industrial and domestic motors. The manufacturers and consumers of these motors are now keen to include condition-monitoring equipment, which improves the safety and reliability of the equipment. Early detection of abnormalities in the motors will help to reduce the fault number and associated repair costs. In this paper, we propose a Computer aided Online Fault Diagnosis Technique which monitors the online condition of motor; diagnose faults, insulation condition, working temperature, possibilities of occurrence of short circuit faults. Sensing elements are embedded at various deterministic points in the motor, the analog o/p which is digitized, Converted to RS-232 Compatible Levels and interfaced with the PC. A special GUI is designed to enable the user to detect faults occurring inside the motor and will also facilitate in making an analysis of the above conditions mentioned. Thus, the user can get to know about the motors performance and can take necessary steps to improve the life of the motor. This technique is best suited for motors above 10hp. Our system also provides an 8051 micro controller based circuit which will find the power factor of the system and switches on the capacitor bank when operating power factor is found to be different from the desired value, Keywords: Condition monitoring, Fault Diagnosis, Sensing Elements, Micro controller based Power factor control, Capacitor bank.

device available. It is used to drive numerous important propulsion and medium transfer unit. The induction machine is considered inherently reliable due to its robust and relatively simple design. That said, the induction machine does fail most usually as a result of aging or poor construction and, if failure is of a catastrophic nature, hazards to production, safety, and the environment can often fault. The optimum way of negating these dangers is by the condition monitoring of the induction machine. This allows early identification of the degradation of the machine health and hence facilitates a proactive response minimized downtime and maximizes productivity. Condition monitoring of electric machinery can significantly reduce the cost of maintenance and the risk of unexpected failures by allowing the early detection of potentially catastrophic faults. In condition-based maintenance, one does not schedule maintenance or machine replacement based on previous records or statistical estimates of machine failure. Rather, one relies on the information provided by condition monitoring systems assessing the machine's condition. Thus the key for the success of condition-based maintenance is having an accurate means of condition assessment and fault diagnosis. II. INDUCTION MOTOR FAULTS

I. INTRODUCTION

lectric motors play a very important role in the safe

and efficient running of industrial plants and processes. Early detection of abnormalities in the motors will help to avoid expensive failures. The induction machine is the single most common electromechanical energy conversion

Induction machine failure surveys have found the most common failure mechanisms in induction machines. These have been categorized according to the main components of a machine stator related faults, rotor related faults, bearing related faults and other faults. 1) Stator faults resulting in opening or shorting of one or more of phase winding.

2) Abnormal connection of stator windings. 3) Broken rotor bar or cracked rotor end rings. 4) Static and /or dynamic air-gap irregularities. 5) Bent shaft (akin to dynamic eccentricity) 6) Shorted rotor field winding. 7) Bearing and gear box failures. III. VARIOUS TYPES OF FAULTS AND THEIR DETECTION TECHNIQUES On-line fault detection uses measurements taken while a machine is operating, to determine if a fault exists. Fig. (I) shows a block diagram of the general approach Most of the faults occurring in an Induction Motor produce one or more symptoms as given below [1], [2]: 1) Unbalanced air gap voltages. 2) Increased torque pulsations. 3) Decreased average torque. 4) Increased losses and reduction in efficiency. 5) Excessive heating, Leakage Current in Stator Windings 6) Change in Rotor Time Constant. Different types of sensors can be used to sense the characteristic signals resulting from these faults. Various signal processing techniques can be applied to these sensor signals to extract particular features which are sensitive to the presence of faults. Finally, in the fault detection stage, a decision needs to be made as to whether a fault exists or not. IV. SENSING THE FAULTS

8) Motor-current signature analysis (MCSA); 9) PD Measurements 10) Current Sequence Detection 11) Model, artificial intelligence, and neural network based techniques. [17], [18] Inspite of having such methods, there hasnt been much work done till date on interfacing various sensing devices (to detect some common faults) to PC and monitoring various parameters through the vital data obtained on the screen, online. A. Bearing faults:

Almost 40%50% of all motor failures are bearing related. Basic vibration signal processing [3] has got several advantages over its contemporary methods like [6], [7]. Piezo sensors are to be installed at various deterministic points in the motor and the characteristic vibrations resulting from piezosensors are sent to the processor of PC and compared with those stored healthy vibration templates for detection of bearing faults. Vibrations detected by peizo transducers are further processed in Real-time analyzer software DSSF3. The vibrations from a bearing are compared with the ideal vibrations resulting from a healthy bearing to determine the fault. B Online stator Insulation Monitoring:

Sensing the faults Laboratory Testing & Field Experience

Signal Processing

Expert Knowledge
Figure 1

Fault Detection

For the purpose of detecting such fault-related signals, many diagnostic methods have been developed so far. These methods to identify the above faults may involve several different types of fields of science and technology. They can be described as follows [1],[2],[9]: 1) Electromagnetic field monitoring, search coils, coils wound around motor shafts (axial flux-related detection); 2) Temperature measurements; 3) Infrared recognition; 4) radio-frequency (RF) emissions monitoring; 5) Noise and vibration monitoring; 6) Chemical analysis; 7) Acoustic noise measurements;

It is shown in industrial surveys and other studies on machine reliability that the stator winding insulation is also one of the most vulnerable components used in an ac electric Machine. If the insulation condition can be assessed online, more accurate and reliable diagnostic information on insulation condition and its remaining life can be provided to the machine user or operator. The methods available for online stator insulation monitoring include thermal monitoring, chemical monitoring (ozone, tagging compound monitoring), phase and Ground fault relay monitoring, and online partial discharge monitoring The main root causes of insulation failure that is common in random and form wound machines can be summarized as: 1) Delamination or cracking of insulation due to thermal overload or cycling; 2) Abrasion of insulation due to vibration of loose coils or abrasive particles; 3) Degradation due to repetitive electrical stresses; and 4) Electrical tracking or chemical degradation due to contamination The dielectric strength of wound rotor conductor insulation is a direct proportionality of the magnitude of leakage current existing on the insulation. To achieve this, miniaturized current sensors are placed on the insulations, to detect the flow of leakage current due to the failure of the insulation, so that the fault can be detected initially and rectified before a heavy damage occurs. The integrated circuits of the series CS60 will give the service of the current sensors which measures the surface

current. A sensor embedded on a conductor, for experimental analysis can be seen in the figure 2.

(logic 1 and 0) by the A/D Converter. Whenever the A/D Converter produces logic 1, it means that the temperature at the spot has crossed the safe operating temperature. A counter, controlled by a 555Timer is going to count the number of logic 1's occurring at a particular spot for a specified sampling period, which is set in accordance to the age of the motor. Therefore, the spot at which maximum number of 1s has occurred is the spot where conductors are more susceptible for insulation breakdown.

Figure 2

Proper signal conditioning is done to the O/P obtained from the sensor and is then digitized, interfaced with PC. Therefore the leakage current existing on the insulation can be monitored from time to time and when it reaches undesirable levels, it can be replaced C Online Temperature Monitoring:
Figure 3

Temperature inside the machine is also monitored online with the help of an integrated circuit LM35, a temperature sensor. This integrated circuit has the following features: 1) It is calibrated linearly in Celsius. 2) +10mV/0C is the scaling factor. 3)0.50C accuracy guaranteed at 1250C. 4) Rated for -550C to 1500C. This IC is embedded in those regions of the stator frame where there is a possibility of HOT SPOTS. This digital IC is interfaced with the PC by means of suitable interfacing techniques so that the temperature of hot spots can be conveniently monitored. A comparator circuitry is also arranged on the frame so that it generates a beep sound as and when the temp.exceeds a particular limit.
Figure 4 Indicates Circuit for Hot Spot Identification

Online Hot Spot Detection:: E Broker rotor Bars and Ring Faults: Unlike stator design, cage rotor design and manufacturing has undergone little change over the years. As a result, rotor failures now account for around 5%10% of total induction motor failures (Bonnett and Soukup [7], Kliman et al. [8],) the reasons for rotor bar and end-ring breakages are several. The following can cause those [9]: 1) Thermal stresses , produced due to thermal overload and unbalance, hot spots, sparking (mainly fabricated rotors); 2) Mechanical stresses due to loose laminations, fatigued parts, bearing failure, etc 3) Magnetic stresses caused by electromagnetic forces, electromagnetic noise 4) Dynamic stresses arising from shaft torques, centrifugal forces, and cyclic stresses; 5) Residual stresses due to manufacturing problems;

The proposed circuit is helpful for determining the region where there is more possibility for the occurrence of a hot spot and where there is more possibility for the Insulation breakdown to occur. Thermistors are placed at those spots, inside the stator which are susceptible to easy temperature rise (based upon the past history of the motor).Fig3 shows the stator of an induction motor. Thermistors are placed at different locations (Indicated in red). They are located at places where the possibility of the fault is predicted. Let the safest operating temperature be assumed to be 65C. The voltage corresponding to this temperature is applied as Reference Voltage to the Inverting terminal of an OpAmp. The output voltage corresponding to Hot-spot is applied to the Non-Inverting terminal of the Op-amp. Whenever the temperature of spot exceeds the safest operating temperature, an output voltage is produced by the op-amp, which is rectified and converted to digital data

6) Environmental stresses caused by for example contamination and abrasion of rotor material due to chemicals or Moisture; Search coils are placed internally around stator tooth tip and yoke and externally on the motor frame. Broken bar faults can be detected by time- and frequency-domain analysis of induced voltages in search coils [10]. Detection of these faults is also possible by frequencydomain analysis of shaft flux or more generally axial leakage flux, which is monitored by using an external search coil wound around the shaft of a machine. [11] Therefore, search coils form a Data acquisition unit whose data would be sent to PC via suitable interfacing unit and F-D analysis can be made by running a program stored in the PC specifically for this purpose V. MICROCONTROLLER BASED POWER FACTOR CONTROL OF MOTOR It is common to have motors operating at lower values of Power factor and drawing high current from supply mains. In case they are installed in farms where 15-20 motors are connected to a single transformer and if such a motors working condition has to be analyzed at a monitoring station, away from the farm, it becomes necessary to test it under realistic conditions prevailing in the farm. So, we have designed 8051 micro controller based PF equipment which is going to ensure that the working PF is varied regularly as per our requirement so as to create different testing conditions for the motor Desired PF>Operating PF START Desired PF< Operating PF

It becomes essential to do such a test as the stator current (current drawn from the mains is different at different PFs and the severity of insulation breakdown is dependent upon the electrostatic stress applied on them, which is a function of the stator current). The flow chart for implementation is shown here. Therefore a detailed analysis on performance of motor at various PFs can be carried out and its lifetime can be estimated. Possibility of breakdown is better analyzed by using the conventional tests because all possible working conditions are used. VI. RS-232 SIGNAL INTERFACING: The RS-232 standard (EIA/TAI-232-E) is a standardized method while interfacing any hardware controller to the PC. It is a high-level signal output between +3 to +15 volts and a low-level as being between -3 and -15 volts. Below is an illustration of those logic levels as defined by the RS232 standard, A low level (-3V to -15V) is defined as a logic 1 and is referred to as marking. A high level (+3V to +15V) is defined as logic 0 and is referred to as spacing. The RS-232 standard breaks down the various signals into four categories; data, control, timing, and common. These signals are very numerous and most applications do need most if not all of the signal connections. These PC based health-analyzing systems only need a few of these signals because the data protocol used requires no signal handshaking. This system has two RS-232 interface plugs and cable connections.

Measure the power factor value

Figure 6

Store its value in register VII. GRAPHICAL USER INTERFACE FOR CONDITION MONITORING Fig (7) illustrates a Graphical user interface (GUI). GUI has been designed by us on an experimental basis to simplify the work of the operator, monitoring the performance of the machine. Presently we have designed GUI in MATLAB for monitoring 4 parameters. i.e. Bearing fault detection, working temperature, leakage current of stator winding, temperature inside the motor, rotor time constant (using extended kalman filter analysis Program embedded in the system.).The Condition of the machine is analyzed by comparing the monitored values with ideal values recorded from a healthy machine. Each parameter is assessed with a particular value of tolerance.

Switch on the capacitive bank

Compare it with desired PF

Switch on the inductive bank

Desired PF=Operating PF
STOP
Figure 5 : 8051 Based Power Factor Controller Flowchart

Figure 10: Healthy Motor Rotor Resistance

Figure 7: Graphical User Interface

VIII. RESULTS A Bearing Fault Detection by Vibration Analysis using DSSF3 Real Time Analyzer Software: Simulation studies have been done on a healthy and faulty 3HP, 400 V, 50HZ squirrel cage induction motor

Figure 11: Faulty Motor Rotor Resistance

Figure 8: For a machine with healthy bearings

Figure 12:

Healthy Motor Rotor Inductance

Figure 9: For a machine with faulty bearings

B Estimation of rotor time constant using embedded kalman filter algorithm: Simulation studies have been done on a healthy and faulty 3HP, 400 V, 50HZ squirrel cage induction motor to estimate rotor time constant, in MATLAB.

Figure 13:

Faulty Motor Rotor Inductance

REFERENCES: Type Healthy Faulty C Rotor Resistance 2.60 ohm 2.71 ohm Rotor Inductance 660 mH 910 mH Rotor Time Constant 0.2538 s 0.3357 s
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Temperature Monitoring of Induction Motors:

Tempaerature Vs Time graph has been plotted for healthy and faulty motor at full load. The data aquired from the sensing system is interfaced with the PC and displayed in Matlab GUI. The graph is shown below. Blue curve is for healthy motor (3HP,400V,50Hz), red color curve is for Faulty motor (3HP,400V,50Hz).

Fig 14 IX.CONCLUSION The paper discussed on some of the Innovative and efficient methods of online Diagnosis of the induction motor. The techniques discussed are simple, cost effective and create a realistic working environment for effective fault analysis. Results obtained for Online Detection of Bearing faults, Rotor Time Constant, Temperature Monitoring have been shown in the paper. Though we had monitored leakage currents, in case of a faulty motor, we have only included a provision for instantaneous display of leakage current in GUI. In future studies, we will extend the system to monitor various other parameters as well as maintain a data base for effective condition monitoring. ACKNOWLEDGEMENT We would like to thank Dr.H.S.Saini, Principal, Prof.P.Parthasaradhy, Dean-SW, Assoc.Prof Narendra Kumar, Head, Dept of EEE and Assoc. Prof Jagbandhukar of GuruNanak Engineering College (GNEC) for their valuable guidance, support and suggestions