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Finite element diagnosis of rotor faults in induction motors based on low

frequency harmonics of the near-magnetic field

Conference Paper · October 2011

DOI: 10.1109/DEMPED.2011.6063623 · Source: IEEE Xplore

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 Finite Element Diagnosis of Rotor Faults in
Induction Motors based on Low Frequency
Harmonics of the Near-Magnetic Field
A. Ceban(1), V. Fireteanu(2), R. Romary(1), R. Pusca(1) and P. Taras(2)

Φ
Abstract -- The influence of different faults of squirrel-cage
rotor in induction motors on the near-magnetic field are
studied in this paper. The 2D finite element analysis of
electromagnetic field is used to investigate the detection of
broken rotor bars and rotor eccentricity faults. This analysis is
focused on the low frequency harmonics of the near-magnetic
field, which are much modified under faulty conditions and less
attenuated by the motor frame.
Index Terms--Broken bars, fault diagnosis, finite element
analysis, rotor eccentricity.
I. INTRODUCTION
F OR many industrial applications it is interesting to use
the noninvasive measurement methods to detect the
faults in induction motors without stopping the motor
outside the motor and the harmonics of the near-magnetic
field.
Section II of this paper is devoted to the presentation of
some experimental results with the coil sensor technique [8]
related to the influence of a broken rotor bar on the magnetic
field outside the motor. Section III describes the finite
element model of a squirrel cage induction motor able to
investigate the near-magnetic field and the section IV
analyzes the time variation and the harmonics of the output
voltages in the coil sensors of this model. Results related the
lines of the near-magnetic field for the healthy and faulty
motors, the time variation of the magnetic flux density in a
point and the low frequency harmonics of the magnetic field
are presented in the Section V.

II. EXPERIMENTAL ASCERTAINMENTS

operation. A diagnostic technique which can predict a failure
and to prevent the total damage is therefore of great The flux signature analysis is very simple and completely
importance [1], [2]. noninvasive; also it is more efficient than the classical motor
Fault detection has been already largely investigated, current analysis to detect the stator and rotor faults in
using different techniques such as those based on the motor induction machines [12], [13].The tests were performed on a
vibrations or motor current signature analysis [3]-[7]. healthy and a faulty motors with one broken rotor bar
Recently, methods based on the analysis of external (Fig. 1). A coil sensor has been used to investigate the
magnetic field have been developed; their advantages are the magnetic field outside the motors. It is circular of 10 cm2
noninvasive investigation and simplicity of implementation area with the coil constituted of 1200 turns.
[8], [9]. The noninvasive evaluation of a motor healthy state The sensor output voltage is transmitted to a PULSE
takes into account the reality that any fault is more or less Brüel&Kjær analyzer (Fig. 1), which performs signal
reflected in the near vicinity of the machine [8]-[11]. In this processing and provides its spectrum.
context, this paper studies the influence of different faults in
the squirrel-cage induction motors on the near-magnetic
field, such as broken rotor bars and eccentricity. The interest
is focused on the low frequency harmonics of this field,
which are less attenuated during their penetration through
the stator magnetic core and the frame of the machine.
The study considers the interaction of the broken bar fault
with rotor eccentricity and allow to analyze the influence of
each or both faults in the modification of the external
magnetic field. The 2D finite element models of the motor
are used to compute the electromagnetic field inside and

(1)
A. Ceban, R. Romary and R. Pusca are with the Univ. Lille de Nord
France, F-5900 Lille, France and UArtois, LSEE, F-62400 Béthune, France
(e-mails: apceban@gmail.com, raphael.romary@univ-artois.fr,
puscaremus@hotmail.com). Fig. 1. Test-bed used for experimental analysis.
(2)
V. Fireteanu and P. Taras are with POLITEHNICA University of
Bucharest, Electrical Engineering Faculty, EPM_NM-Lab, 313 Splaiul In case of the Ox sensor position (see Fig. 1), the coil
Independentei, 060042 Bucharest, Romania (e-mails:
virgiliu.fireteanu@upb.ro, petrica_taras@amotion.pub.ro). turns are vertical and for the Oy position they are horizontal.
 The spectra of the output voltage for the Ox sensor
position are presented in Fig. 2 for the healthy motor and in
Fig. 3 for the faulty motor. In this position, the output
voltage is the image of the radial component of the magnetic
field outside the motor. It can be noticed that spectrum
components less than 50 Hz increase in amplitude when one
rotor bar breaks.
Fig. 2. FFT spectrum of the coil sensor voltage in position Ox – case of the
healthy motor.
Fig. 3. FFT spectrum of the coil sensor voltage in position Ox – case of one
broken rotor bar.
Figs. 4-5 show the corresponding spectra for the Oy
position of the coil sensor. In this case, the output voltage is
the image of the azimuth component of the magnetic field
outside the motor.
Fig. 4. FFT spectrum of the coil sensor voltage in position Oy – case of the
healthy motor.
Fig. 5. FFT spectrum of the coil sensor voltage in position Oy – case of one
broken rotor bar.
As shown in Figs. 2-5 the harmonic at 26.25 Hz increases
in the ratio 9.43/1.49 = 6.33 in case of the Ox sensor position
and in the ratio 4.10/0.76 = 5.38 in case of the Oy position.
III. DESCRIPTION OF THE FINITE ELEMENT MODELS FOR
NONINVASIVE DIAGNOSIS OF INDUCTION MOTOR
The FLUX2D circuit, geometry and mesh presented in
Fig. 6(a)-(c) correspond to the same 4 poles induction motor,
4 kW, 3 x 380 V, fn = 50 Hz used in the experimental tests.
The 2D computation domain, infinitely extended, contains
the stator and the rotor cores - magnetic and nonconductive
regions, the 48 stator slots - nonconductive, nonmagnetic
and source regions, the airgap of 0.5 mm thickness and
regions of solid conductor type - the rotor slots, the rotor
shaft and the motor frame of 6 mm thickness [Fig. 6(a)].
(a)
(b)
(c)
Fig. 6. The finite element model: (a) geometry; (b) electric circuit; (c) mesh
zoom.
The state variable of the electromagnetic field - the
magnetic vector potential A(x,y,z,t), satisfies the following
differential equations [14]-[17]:
curl [1 μ ⋅ curl A] + ( ∂A ∂t ) ρ = J s ( x, y, z , t ) ; div A = 0
where μ is the magnetic permeability, ρ is the resistivity and
Js is the current density in the stator slots. The term (∂A/∂t)/ρ
is the density of the induced current that is different from
zero only in the solid conductor regions of the rotor slots.
In the field model considered in this paper the source
current density has the structure Js[0,0,Js(x,y,t)]. As
rotor bar and constant speed and in Fig. 9 for one broken bar
and constant load torque. The corresponding rms values are
421.3 mV, 427.2 mV and 428.1 mV. The same very small
(1) differences characterise the amplitude of the 50 Hz voltage
harmonic [Figs. 7-9 (down)]. Contrariwise, the spectra and
the amplitudes of the harmonics with very low frequency,
1.25 Hz, 2.5 Hz, 3.75 Hz, ... , 12.5 Hz, are completely
different for the healthy motor and for the motor with one
broken bar.
1

consequence, the vector potential As[0,0,As(x,y,t)] is oriented 0.5

Voltage (V)
along the Oz axis and not depends on the coordinate z and 0
the second equation (1) is implicitly satisfied. -0.5
The electric circuit [Fig. 6(b)] attached to the field model -1
contains twelve components of stranded coil type, which 0.6 0.7 0.8 0.9 1
Time (s)
1.1 1.2 1.3 1.4

correspond to the four zones of each of three phases of the

0.8
stator winding. The inductances Lσ1f correspond to the part
of the stator winding outside the stator magnetic core and the 0.6

Voltage (V)
voltage sources UU, UV, UW are phase-to-null voltages of the 0.4

symmetric three phase motor supply. Four components of 0.2

stranded coil type, correspond to the two coil sensors and 0

0 10 20 30 40 50 60 70 80 90 100
two resistors are considered for sensor voltage measurement. Frequency (Hz)
The macro-component squirrel-cage reflects the 28 rotor 4
x 10
-4

bars and the electric parameters of the squirrel cage outside 3

Voltage (V)

the rotor slots.

2
Since the main interest of the finite element model is the
1
non-invasive fault diagnosis based on magnetic field outside
the motor, the mesh of the computation domain [Fig. 6(c)] is 0
0 2 4 6 8 10 12 14
fine enough inside and outside the motor and it is also fine Frequency (Hz)

enough in the regions of solid conductor type, in order to

have a good accuracy of the numerical solution.
The nonlinear magnetic cores are characterised by the
saturation at 2 T, the initial relative magnetic permeability is
4000 and the curvature coefficient is 0.3. The squirrel-cage
Fig. 7. Voltage time variation (up) and FFT spectrum (down) of Sensor Ox
for the healthy motor and constant speed.
1

is aluminium made of resistivity 0.027 μΩm and the frame 0.5

Voltage (V)

of the motor is Al-Si alloy made of resistivity 0.045 μΩm. 0

The rotor shaft is magnetic steel made of resistivity -0.5
0.2 μΩm, saturation 1.8 T and initial relative permeability -1
1800. 0.6 0.7 0.8 0.9 1
Time (s)
1.1 1.2 1.3 1.4

The step-by-step type in time domain analysis of the

0.8
electromagnetic field considers the time step values 1 ms.
The steady state motor operation is reached in about 0.6 s, so 0.6
Voltage (V)

that the time interval (0.6…1.4) s is considered for the 0.4

results analysis. As further explained, 0.8 s is the period of 0.2

the electromagnetic field outside the motor when the rotor 0

0 10 20 30 40 50 60 70 80 90 100
has the speed 1425 rpm. Frequency (Hz)

The field-circuit-motion model of the motor takes into

-3
x 10
1.5
account two variants of motor operation: constant rotor
Voltage (V)

speed 1425 rpm, respectively the slip value s = 0.05 and 1

constant mechanical load 26 Nm. 0.5

IV. LOW FREQUENCY HARMONICS OF COIL SENSORS 0

0 2 4 6 8 10 12 14
VOLTAGE OUTPUT Frequency (Hz)

The time variation and the harmonics of the output Fig. 8. Voltage time variation (up) and FFT spectrum (down) of Sensor Ox
voltage of Ox coil sensor are presented in Fig. 7 for the for one broken rotor bar and constant speed.
healthy motor and constant speed, in Fig. 8 for one broken
 1 In the case of the healthy motor, Fig. 10, the lines of the
0.5 near-magnetic field around the motor are identical for all
Voltage (V)

0 four poles. For all other cases, Figs. 11-13, the symmetry of
-0.5
the four poles of the near-magnetic field is more or less
-1
affected by the rotor faults.
0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4
Time (s)

0.8

0.6
Voltage (V)

0.4

0.2

0
0 10 20 30 40 50 60 70 80 90 100
Frequency (Hz)
-3
600 ms 1000 ms 1400 ms
x 10
1.5
Fig. 10. Lines of the near-magnetic field for the healthy motor.
Voltage (V)

0.5

0
0 2 4 6 8 10 12 14
Frequency (Hz)

Fig. 9. Voltage time variation (up) and FFT spectrum (down) of Sensor Ox
for one broken rotor bar and constant load.

The harmonic with the frequency sfn = 2.5 Hz, which is 600 ms 1000 ms 1400 ms
practically inexistent in the case of healthy motor (Fig. 7) Fig. 11. Lines of the near-magnetic field for motor with one broken bar.
has around 0.6 mV amplitude for one broken bar and
constant speed (Fig. 8) and around 0.7 mV for of one broken
bar and constant load (Fig. 9).

V. STUDY OF MAGNETIC FIELD OUTSIDE THE MOTOR – THE

NEAR-MAGNETIC FIELD
In order to show why the electromagnetic field finite
element computation is important for faults identification,
this section presents the results of motor operation at 600 ms 1000 ms 1400 ms
constant mechanical load, for the healthy motor, for one Fig. 12. Lines of the near-magnetic field for the motor with rotor
broken bar, for 0.2 mm static eccentricity of the rotor and for eccentricity.
both motor faults – one broken bar and eccentricity.
In the case of the heathy motor, the speed has very small
oscilations, in the range (1428.4…1428.8) rpm. For a broken
bar the speed oscilates in the range (1423.8…1428.5) rpm,
for rotor eccentricity in the range (1428.3…1428.9) rpm and
for both faults in the range (1424.0…1429.2) rpm. This
variation has been experimentaly proved by the appearance
of the harmonic 3sfn of the external magnetic field [9].
600 ms 1000 ms 1400 ms
A. The Field Lines of the Near-Magnetic Field Fig. 13. Lines of the near-magnetic field – one broken bar and eccentricity.
The charts of the magnetic field lines outside the motor
for the time steps 600 ms, 1000 ms and 1400 ms are B. Low Frequency Harmonics of the Magnetic Flux
presented in Fig. 10 for the healthy motor, in Fig. 11 for one Density
broken rotor bar, in Fig. 12 for rotor eccentricity and in
The time variation radial component Bx of magnetic flux
Fig. 13 for both faults – broken bar and eccentricity.
density in the center of the Ox sensor and azymuthal
For the value 1425 rpm of the rotor speed, the
component By in the center of the Oy sensor are studied in
corresponding period of the rotor currents is
order to diagnose the motor faults based of the magnetic
T = 1000 / (sfn) = 400 ms. Thus, as Figs. 10-13 show, the
field low frequency harmonics. These curves are presented
approximate period of the near-magnetic field is the double
in Fig. 14 for the healthy motor, in Fig. 15 for one broken
2T = 800 ms of the period of rotor currents. This explains the
bar, in Fig. 16 for rotor eccentricity and in Fig. 17 for both
choice for the time steps 600 ms, 1000 ms and 1400 ms for
faults: one broken bar and 0.2 mm rotor eccentricity.
the magnetic field lines representation.
 -4 X Component -4 X Component
x 10 x 10
Flux density (T) 2 2

Flux density (T)

1 1

0 0

-1 -1

-2 -2
0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4
Time (s) Time (s)

-4 Y Component -4 Y Component
x 10 x 10
2 2
Flux density (T)

Flux density (T)

1 1

0 0

-1 -1

-2 -2
0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4
Time (s) Time (s)

Fig. 14. Time variation of the magnetic flux density for the healthy motor. Fig. 17. Time variation of the magnetic flux density for one broken rotor
bar and rotor eccentricity.

2
-4
x 10 X Component
The comparison of all under 10 Hz harmonics for the
healthy motor (0BC) and for one broken rotor bar (1BC) in
Flux density (T)

1
Fig. 18 states the choice for the 1.25 Hz and 6.25 Hz
0 harmonics to characterize the broken bar fault.
-1

-2
0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4
Time (s)

-4 Y Component
x 10
2
Flux density (T)

-1

-2
0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4
Time (s)
(a)

Fig. 15. Time variation of the magnetic flux density for one broken rotor
bar.

-4 X Component
x 10
2
Flux density (T)

-1

-2
0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 (b)
Time (s) Fig. 18. Amplitudes of low frequency harmonics for the healthy motor and
the motor with one broken bar: (a) Bx harmonics; (b) By harmonics.
-4 Y Component
x 10
2

As shown in Fig. 19 the increase of the all harmonics

Flux density (T)

0 amplitudes with frequency under 10 Hz of the two

components of the magnetic flux density it is also evident
-1
when a rotor excentricity exists (Ecc + 0BC) or in the case of
-2
0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4
both motor faults (Ecc + 1BC). Related to the Bx component
Time (s) in Fig. 19(a) the most important increase characterises the
Fig. 16. Time variation of the magnetic flux density for rotor eccentricity. 6.25 Hz harmonic when one rotor bar is broken or when both
faults are present. In case of eccentricity the harmonic at
7.50 Hz is the most important for such a fault diagnostic.

(a)
(b)
Fig. 19. Amplitudes of low frequency harmonics for healthy and faulty
motors: (a) Bx harmonics; (b) By harmonics.
In case of the By component, since the amplitudes of the
2.5 Hz are higher than those of the Bx component, it is this
low frequency harmonic to be considered for motor faults
diagnosis.
Two harmonics with the frequency 21.25 Hz and
26.25 Hz (Fig. 20) have much higher amplitudes than the
under 10 Hz harmonics. The first harmonic is not so affected
by the eccentricity fault, but the second is very efficient for
diagnosis of all three motor faults considered in this study:
1BC, Ecc + 0BC, Ecc + 1BC.
Fig. 20. Amplitudes of two Bx harmonics over 10 Hz for healthy and faulty
motors.
VI. CONCLUSIONS
This paper studies a very simple and efficient method for
the noninvasive diagnosis of broken bars and rotor
eccentricity faults in squirrel-cage induction motors, based
on the evaluation of low frequency harmonics of the near-
magnetic field.
The increase of the amplitudes of the magnetic field
harmonics for faulty motor with respect the healthy motor is
different from one harmonic to another and from a motor
fault to another. Consequently, the first step in the diagnosis
strategy implementation for motors in operation or during
the new motors design it is the choice based on finite
element models of the most appropriate harmonic which
should be used for fault detection.
VII. REFERENCES
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VIII. BIOGRAPHIES
Andrian Ceban was born in Leova, Moldova, in 1982. He received the
Master’s degree in electrical engineering from the Technical University of
Moldova, Chisinau, Moldova, in 2008. He is currently Ph.D. student in
electrical engineering at the Laboratory of Electrical Systems and
Environment (LSEE), Artois University, Béthune, France. His research
interests include diagnosis and numerical modeling of electrical machines.
Virgiliu Fireţeanu was born Runcu-Dambovita, Romania, on November 7,
1947. He graduated in 1970 the former Polytechnic Institute of Bucharest,
Electrotechnical Faculty. From 1994 he is Full Professor of POLITEHNICA
University of Bucharest, Electrical Engineering Faculty. His actual field of
interest it is the finite element analysis of electro-mechanical and electro-
thermal energy conversion systems. He animates the activity in higher
education and research and the EPM_NM Laboratory
(http://www.amotion.pub.ro/~epm).
Raphaël Romary received the Ph.D. from Lille University in 1995 and the
D. SC degree from Artois University in 2007. He is currently Full Professor
in that University and researcher at the Laboratory of Electrical Systems and
Environment (LSEE). His research interest concerns the analytical modeling
of electrical machines with applications to noise and vibration, losses,
electromagnetic emissions, diagnosis.
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Remus Pusca was born in Medias, Romania, in 1972. He received in 1995
the electrical engineering degree from Technical University of Cluj-Napoca,
Romania. He obtained in 2002 Ph.D. degree in electrical engineering, from
the University of Franche-Comté, France. Since 2003 he has joined the
Laboratory of Electrical Systems and Environment (LSEE). He is Associate
Professor at the Artois University. His research interest is control of
electrical systems and diagnosis of electrical machines.
Petrică Taraş was born in Călăraşi, Romania, on June 22, 1983. He
graduated from the POLITEHNICA University of Bucharest, Romania. His
main interest resides in applied finite element modeling. He is a member in
the EPM_NM laboratory team. He is currently pursuing a Ph.D. degree in
the area of rails induction heating before hardening.