Ain Shams Engineering Journal (2013) xxx, xxx–xxx

Ain Shams University

Ain Shams Engineering Journal

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ELECTRICAL ENGINEERING

2D finite element analysis and force calculations

for induction motors with broken bars
Hanafy Hassan Hanafy, Tamer Mamdouh Abdo *, Amr Amin Adly

Electrical Power and Machines Department, Faculty of Engineering, Cairo University, Giza 12613, Egypt

Received 23 June 2013; revised 20 November 2013; accepted 22 November 2013

KEYWORDS Abstract In this paper an ABC transient model of the three phase induction motor is developed
Squirrel-cage induction that depends on self- and mutual inductance calculations based on accurate finite element analysis
motors; (FEA). This model can represent both healthy and broken bars’ conditions. The effects of that type
Finite element analysis of fault on the stator current, rotor bar currents distribution, the forces exerted on the rotor bars,
(FEA); the motor speed and motor torque are studied. It was observed that broken bar faults will cause
Broken rotor bars fluctuations in the stator peak current and in the motor speed and torque. It was found that the
asymmetry in the rotor bar currents will lead to asymmetrical distribution of the radial and tangen-
tial forces affecting the bars. The asymmetry in the tangential forces causes the fluctuations in the
motor torque, while the asymmetry in the radial forces will increase the mechanical stresses on the
rotor shaft.
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1. Introduction For detailed and accurate analysis of motor performance in

Robustness and reliability made the squirrel-cage induction
motor the most used motor in industrial and domestic applica-
tions. Squirrel-cage induction motor faults are categorized into
electrical and mechanical faults. Electrical faults are divided
into stator and rotor faults. Rotor broken bars are one of
the most common faults. This fault results in asymmetrical
operation of the induction motor which leads to deterioration
of its performance.
* Corresponding author. Tel.: +20 1227124247.
E-mail address: tam2k0@gmail.com (T.M. Abdo).
Peer review under responsibility of Ain Shams University.
Production and hosting by Elsevier
faulty conditions, an accurate model for the motor in which all
conditions can be considered is of extreme importance. In [1],
basic methods for faulty induction motor modeling have been
mentioned such as magnetic equivalent circuit method, finite
different methods, winding function method, and finite
element method (FEM). A detailed steady state model was
developed to simulate rotor cage and unbalanced voltage
faults in [2]. The transient performance was obtained based
on multi-loop theory in [3,4].
FEM has been introduced as one of the most comprehen-
sive modeling methods. FEM is a technique based on the
magnetic field analysis in which the magnetic circuit geometry,
spatial distribution of stator windings and rotor bars and
nonlinear behavior of ferromagnetic materials is taken into
account. FEM was used to accurately calculate the steady state
equivalent circuit parameters of the induction motor in [5–7].
The parameters for a two-axis model suitable for dynamic

2090-4479  2013 Production and hosting by Elsevier B.V. on behalf of Ain Shams University.
http://dx.doi.org/10.1016/j.asej.2013.11.003

Please cite this article in press as: Hanafy HH et al., 2D finite element analysis and force calculations for induction motors with
broken bars, Ain Shams Eng J (2013), http://dx.doi.org/10.1016/j.asej.2013.11.003
2 H.H. Hanafy et al.

analysis were calculated using finite-element analysis (FEA)
[8,9].
A finite element-state space coupled (CFE-SS) model with
iterative solution was developed in [10], where it was used to
obtain the dynamic performance of the induction motor.
Time-stepping finite element method (TS-FEM) coupled with
circuit and mechanical equations were successfully used to
analyze the transient and steady state performance [11–13].
In [14] the air–gap interface coupling method was used to sim-
ulate the rotor movement with TSFE method. The field-circuit
coupled TS-FEM was improved by using the time-periodic
FEM to reduce the computation time in [15,16]. Multi-slice
time-stepping finite element method (MSTS-FEM) was devel-
oped to include the effects of skewing in [17,18].
A comprehensive time-stepping coupled finite element
approach was used to compute motor performance for differ-
ent broken bar cases in [19]. Some aspects of broken bar faults
have been diagnosed and characterized using TS-FEM in [20].
Performance analysis and thermal field analysis for broken bar
conditions are discussed in [21]. A method for determining the
signatures of electrical faults in the air gap force distribution
and vibration pattern of induction machines was presented
in [22].
This paper presents a study for the performance of induc-
tion motor using self- and mutual inductances calculated from
FEM. It introduces calculations for electromagnetic forces
affecting the rotor bars at different fault conditions. The cases
of one broken bar and two adjacent broken bars are studied at
different instances. The motor performance including the sta-
tor current, bars currents, the developed torque and the motor
speed is discussed. The tangential and radial forces on individ-
ual bars are calculated in the mentioned cases. It was found
that in a healthy motor that the stator current is pure sinusoi-
dal and the bar currents are almost equal, this will lead to sym-

Figure 1 Schematic diagram for the rotor loops (formed by the

bars and end rings) showing the rotor loop currents. Figure 3 Schematic diagram for the rotor loops (formed by the
bars and end rings) showing the rotor loop currents in case of one
broken bar.

Figure 2 The stator-to-rotor mutual inductance as a function of

position as calculated by FEM. Figure 4 The BH curve for the motor material M1000-65D.

Please cite this article in press as: Hanafy HH et al., 2D finite element analysis and force calculations for induction motors with
broken bars, Ain Shams Eng J (2013), http://dx.doi.org/10.1016/j.asej.2013.11.003
2D finite element analysis and force calculations for induction motors with broken bars 3

Figure 5 Phase (a) current for the case of healthy rotor: (a) Complete waveform and (b) zoomed waveform.

Figure 6 Bar currents for healthy rotor at rated conditions. Figure 8 Bar currents for the case of one broken bar at rated
conditions.

Figure 7 Phase (a) current for the case of one broken bar: (a) Complete waveform and (b) zoomed waveform.

Please cite this article in press as: Hanafy HH et al., 2D finite element analysis and force calculations for induction motors with
broken bars, Ain Shams Eng J (2013), http://dx.doi.org/10.1016/j.asej.2013.11.003
4 H.H. Hanafy et al.

Figure 9 Stator Current for the case of two adjacent broken bars: (a) Complete waveform and (b) zoomed waveform.

Figure 10 Bar currents for the case of two adjacent broken bars
at rated conditions. Figure 11 The motor torque at different cases at rated
conditions.

metrical radial forces. The net force on the shaft in this case is
negligible. For broken bar cases, the stator currents are fluctu-
ating, and the bar currents are no longer similar, leading to
asymmetrical the radial forces. The mechanical stresses are
found on the motor shaft and bearings, in broken bar cases,
which may cause eccentricity.
2. Motor inductances calculations
package, using the finite element method (FEM) where nonlin-
ear magnetic characteristics were taken into account.
The flux linking with the stator phases or the rotor loops
can be calculated from the vector magnetic potential as given:
I
/ ¼ A  dl ð1Þ

It is well known that the stator windings of the induction mo-
tor are divided into three symmetric phases and that the cage
rotor constitutes bars that are interconnected with two rings,
one from each side. It can be assumed that the current in the
rotor flows in loops where each rotor loop is formed of two
bars and two ring segments as shown in Fig. 1.
The self- and mutual inductances of the motor are calcu-
lated using 2D model for the induction motor. The model
has been analyzed, by utilizing a commercially available
To calculate the self-inductance for stator phases, the
model is solved with only one energized stator phase. The
self-inductance will be as follows:
/ii
Lsii ¼ ð2Þ
Ii
where i = 1, 2 or 3 and /ii is the flux linking the phase number
i due to current in the same phase. While the mutual induc-
tance is calculated using the following:

Please cite this article in press as: Hanafy HH et al., 2D finite element analysis and force calculations for induction motors with
broken bars, Ain Shams Eng J (2013), http://dx.doi.org/10.1016/j.asej.2013.11.003
2D finite element analysis and force calculations for induction motors with broken bars 5

The mutual inductance between rotor loops can be ex-

pressed using the fundamental component only since the har-
monic components could be neglected. It can be expressed as
follows:

Mrhm ¼ Lor cosððh  mÞaÞ; ð7Þ

where h and m = 1, 2, . . . , Nb refer to a rotor cage loop num-

ber (h „ m), lr is the rotor leakage inductance, Lor is the rotor
magnetizing inductance and a is the rotor slot pitch.
It should be pointed out that the mutual inductances
between stator phases and rotor loops, as shown in Fig. 2,
are rotor-position-dependent. The shown waveform was de-
duced using the FEM calculations. From the shape of the
waveform shown, the following stator-to-rotor approximate
mutual coupling, considering only the fundamental compo-
nent, expression may be adopted:
 
2p
Mnm  Losr cos h  k þ ðm  1Þa ; ð8Þ
3
Figure 12 The motor speed at different cases at rated conditions.
where k = 0, 1 or 2, n = a, b or c denotes a particular stator
phase and Losr is the maximum mutual coupling.
/ij
Msii ¼ ð3Þ The stator winding resistance is calculated using the
Ii relation:
where i and j = 1, 2 or 3 and /ij is the flux linking the phase Ns lms
number j due to current in phase number i. rs ¼ ; ð9Þ
rAc
The stator self- and mutual inductances can be expressed as
follows: where Ns is the number of turns per phase, lmt is the turn mean
Ls ¼ ls þ Los ; ð4Þ length, r is the conductivity of copper and Ac is the conductor
cross-sectional area.
Los The rotor bar and end ring segment resistances are calcu-
Ms ¼  ð5Þ
2 lated from the following equations.
where ls is the stator leakage inductance and Los is the stator lb
magnetizing inductance. rb ¼ ; ð10Þ
rAb
The self-inductance of rotor loops can be calculated in a
similar manner and expressed as follows: 2pDr
re ¼ Kring ; ð11Þ
Lr ¼ lr þ Lor ; ð6Þ rNb tðDr  Di Þ

Figure 13 For healthy rotor at maximum current in phase (a): (a) Radial forces and (b) tangential forces.

Please cite this article in press as: Hanafy HH et al., 2D finite element analysis and force calculations for induction motors with
broken bars, Ain Shams Eng J (2013), http://dx.doi.org/10.1016/j.asej.2013.11.003
6 H.H. Hanafy et al.

Figure 14 For healthy rotor at maximum current in phase (b): (a) Radial forces and (b) tangential forces.

Figure 15 For healthy rotor at maximum current in phase (c): (a) Radial forces and (b) tangential forces.

where lb is the bar length, Ab is the bar cross-sectional area, Di In case of broken bar faults, the loop containing the broken
is the inner ring diameter, Dr is the diameter at the middle of bar should be referred to the stator using a chording factor as
the bar, Nb the number of bars, t is the ring height and Kring follows:
is a correction factor [23].  
The rotor parameters are referred to the stator side using ð1 þ bÞa
Kwr ¼ sin ; ð15Þ
the effective turns-ratio: 2
Ns Kws
a¼ ; ð12Þ where b refers to the number of broken bars.
Nr Kwr
where
    3. Induction motor modeling
hs sin qa2 s
Kws ¼ sin  ; ð13Þ
2 q sin a2s The voltage differential equations correlating the induction
a motor voltages and currents may be expressed in the following
Kwr ¼ sin ; ð14Þ form:
2
where Nr is the number of turns of the rotor loop (which   
Vs Rss þ pLss pLsr Is
equals one), hs is the stator coil span angle, q is the number ¼ ; ð16Þ
Vr pLrs Rrr þ pLrr Ir
of slots per pole per phase, and as is the stator slot pitch.

Please cite this article in press as: Hanafy HH et al., 2D finite element analysis and force calculations for induction motors with
broken bars, Ain Shams Eng J (2013), http://dx.doi.org/10.1016/j.asej.2013.11.003
2D finite element analysis and force calculations for induction motors with broken bars 7

Figure 16 For the case of one broken bar at maximum current in phase (a): (a) Radial forces and (b) tangential forces.

Figure 17 For the case of one broken bar at maximum current in phase (b): (a) Radial forces and (b) tangential forces.

2 3
Ls Ms Ms
d
where p ¼ while Rss, Rrr, Lss, Lrr and Lsr ¼
dt
, LTrs are given in Lss ¼ 4 Ms Ls Ms 5; ð20Þ
matrix form as shown below: Ms Ms Ls
2 3
rs 0 0
Rss ¼ 4 0 rs 0 5; ð17Þ 2 3
0 0 rs Lr Mr12 Mr13  Mr1Nb
6 Mr12 Lr  7
6 7
2 3 6 Mr13     7
rL rb 0  0 rb Lrr ¼ 6
6
7;
7 ð21Þ
6    7
6 rb rL  0 7 4   5
6 7
6 0     7 Mr1Nb   Lr
Rrr ¼ 6
6 
7; ð18Þ
6    0 77
4 0   rb 5
rb 0  0 rb rL 2 3
Ma1 Ma2 Ma3    MaNb
Lsr ¼ LTrs ¼ 4 Mb1 Mb2    MbNb 5: ð22Þ
rL ¼ 2rb þ 2re ; ð19Þ Mc1  McNb

Please cite this article in press as: Hanafy HH et al., 2D finite element analysis and force calculations for induction motors with
broken bars, Ain Shams Eng J (2013), http://dx.doi.org/10.1016/j.asej.2013.11.003
8 H.H. Hanafy et al.

Figure 18 For the case of one broken bar at maximum current in phase (c): (a) Radial forces and (b) tangential forces.

Figure 19 For the case of two adjacent broken bars at maximum current in phase (a): (a) Radial forces and (b) tangential forces.

It should be mentioned that the above matrices could be mod- For simplicity, (16) may be written in the form:
ified in accordance with the different fault conditions.
For broken bar conditions, as shown in Fig. 3, the loop V ¼ ðR þ pLÞI: ð26Þ
resistance for the loop including the broken bars will be as
By re-arranging (26) to incorporate rotor motion we get:
follows:
rL ¼ 2½ðb þ 1Þre þ rb  ð23Þ dL
V ¼ RI þ LpI þ xr I; ð27Þ
dh
While the mutual inductance between the loop including the
broken bars and the healthy loops will be as follows:  
   dL
b pI ¼ L1 V  L1 R þ xr þ I; ð28Þ
Mrhm  Lor cos ðh  mÞ þ a ; ð24Þ dh
2
where xr is the rotor angular velocity in electrical rad/s.
The mutual inductance between any stator phase and the bro- Moreover, expressions for the developed torque (Te),
ken bar loop mechanical equation of motion and force acting on the mth
   
2p b rotor bar Fm in terms of its current density ðJÞ and flux density
Mnm  Losr cos h  k þ ðm  1Þ þ a ; ð25Þ ðBÞ acting on it may be given by the expressions:
3 2

Please cite this article in press as: Hanafy HH et al., 2D finite element analysis and force calculations for induction motors with
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2D finite element analysis and force calculations for induction motors with broken bars 9

Figure 20 For the case of two adjacent broken bars at maximum current in phase (b): (a) Radial forces and (b) tangential forces.

Figure 21 For the case of two adjacent broken bars at maximum current in phase (c): (a) Radial forces and (b) tangential forces.

1 dL is solved considering nonlinearity in the magnetic properties.

Te ¼ IT I; ð29Þ
2 dh The B–H curve for the motor material is shown in Fig. 4.
J dxr Sample simulation results for three cases are demonstrated be-
Te  TL ¼ ; ð30Þ
 dt 
P low. In specific, simulation results for the cases of; healthy rotor,
Fm ¼ lbSbar Jc  B dS; ð31Þ one broken bar and two adjacent broken bars demonstrated.
For healthy rotor case, the stator current is pure sinusoidal
where TL is the load torque and J is the motor moment of iner- as expected as shown in Fig. 5. The rms currents in the rotor
tia, P is the number of pole pairs and lb is the bar length. bars are similar as shown in Fig. 6. For the case of one broken
It turns out that Eqs. (28)–(30) may be collectively dealt with bars, the stator current peak value is no longer constant. It can
as an initial value problem (IVP). Once this IVP problem is solved, be noticed that the peak value fluctuates as shown in Fig. 7.
currents in the stator phases and the rotor loops may be deter- The rms bar currents are shown in Fig. 8 for the case of one
mined for a given load torque and specific motor parameters. broken bar (bar number 2 as shown in Fig. 3). The currents
are no longer similar compared to the healthy rotor case.
4. Simulation results The rms current in the bars adjacent to the broken bar has in-
creased compared to the healthy case while in the bars away
A 5.5 kW, 380 volts, 4-pole, 48 stator slots and 28 rotor bars from the broken one the current is almost the same as the
induction motor was used to perform the analysis. The model healthy case.

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10
Moreover, for the case of two adjacent broken bars, the
fluctuations in the peak value of the stator current have in-
creased as shown in Fig. 9. The rms bar currents are shown
in Fig. 10, obtained for the case of two adjacent broken bars,
which are bars 2 and 3. In addition to the increase in the cur-
rent in the bars adjacent to the broken bar, it can be observed
that the current in the bars on the opposite side of the broken
one has increased compared to the healthy case. It can be con-
cluded that as the number of broken bars increase, asymmetry
in the current distribution increases.
The motor torque and speed at the different cases described
above are shown in Figs. 11 and 12, respectively. It is obvious
that there are fluctuations in the motor torque in the different
cases of broken bar faults which results in fluctuations in the
motor speed. As the number of broken bars increases, the fluc-
tuations worsen and the average torque decreases.
Forces affecting each bar were calculated using the same
FEM software that was used to calculate the inductances.
For all cases the tangential and radial forces are calculated
at three instants of maximum current in phases (a), (b) and (c).
The radial and tangential forces for the healthy case at
maximum current in phase (a) are shown in Fig. 13. It can
be seen from these figures that, for the case of healthy rotor,
the radial forces are almost symmetric and cancel each other.
On the other hand, the tangential forces, which are responsible
for generating the motor torque, are symmetrical under the
machine poles. The radial and tangential forces for the healthy
case at maximum current in phase (b) are shown in Fig. 14.
Comparing the previous case to the case of maximum current
in phase (b), the distribution of the radial forces has changed
and the maximum force has increased while the average is
almost the same. The tangential force distribution has also
changed in a similar manner. For the case of maximum current
in phase (c), the tangential and radial forces are shown in
Fig. 15. The maximum radial force has increased and the max-
imum tangential force has decreased both compared to the first
case. On the other hand, the negative tangential forces have in-
creased compared to the previous two cases.
Distributions of the tangential and radial forces for the case
of one broken bar corresponding to maximum current in phase
(a) are shown in Fig. 16. It can be observed from Fig. 16a that
the radial forces are asymmetrical in this case, leading to a net
radial force affecting the rotor shaft and, eventually, the bear-
ings. Moreover, the tangential forces are no longer symmetric
under the machine poles as shown in Fig. 16b. The negative
tangential forces cause a decrease in the average torque com-
pared to the healthy case. The force distributions for the case
of maximum current in phase (b) and phase (c) are shown in
Figs. 17 and 18, respectively. An increase in the maximum ra-
dial force compared to the first case can be observed in these
two cases as shown in Figs. 17a and 18a. The maximum tan-
gential force in the case of maximum current in phase (b)
has increased compared to the first case, while in the case of
maximum current in phase (c) it decreased.
Furthermore, distributions for the tangential and radial
forces for the case of two broken bars at maximum current
in phase (a) are shown in Fig. 19. It can be observed from
Fig. 19a that the asymmetry in the radial forces has increased
in comparison with the case of one broken bar. Such increase
in the asymmetry would negatively affect the bearings life time.
Increased asymmetry of the tangential forces, as illustrated by
Fig. 19b, would result in increased torque and speed
Please cite this article in press as: Hanafy HH et al., 2D finite element analysis and force calculations for induction motors with
broken bars, Ain Shams Eng J (2013), http://dx.doi.org/10.1016/j.asej.2013.11.003
H.H. Hanafy et al.
variations. The negative tangential forces cause a decrease in
the average torque compared to the healthy case. The force
distributions for the case of maximum current in phase (b)
and phase (c) are shown in Figs. 20 and 21, respectively. A sim-
ilar pattern to the one observed in the cases of healthy rotor
and one broker bar can be observed when comparing the three
cases studied.
5. Conclusions
This paper presents an efficient model to analyze broken bar
fault conditions for induction motors using a FEM approach
coupled with an ABC transient model. It can be concluded that
broken bar faults lead to fluctuations in the peak value of the sta-
tor current. These faults also lead to asymmetry in the bar cur-
rents that increases as the number of broken bars increase. As a
result for the bar currents asymmetry, fluctuations in the motor
torque are produced which will lead to fluctuations in the speed.
The radial forces are asymmetrical in broken bar cases, leading
to a net radial force affecting the rotor shaft and, eventually, the
bearings. The tangential forces are no longer symmetric under
the machine poles. The negative tangential forces cause a de-
crease in the average torque compared to the healthy case.
The differences between several stator current instances are also
discussed. The proposed approach may be utilized in predicting
the net mechanical stresses on the motor shaft and bearings
which may lead to motor eccentricity and bearing faults. Future
work will include more analysis for the asymmetry in the radial
forces and investigation for its effect on the motor bearing. The
relation between this asymmetry in the radial forces and eccen-
tricity faults will also be studied. The effects of mixed rotor
faults, which include both eccentricity and broken bars, will also
be investigated.
Acknowledgment
The authors would like to thank Dr. A. Abdallah for his valu-
able feedback, remarks and suggestions.
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broken bars, Ain Shams Eng J (2013), http://dx.doi.org/10.1016/j.asej.2013.11.003
11
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Hanafy Hassan Hanafy received his B.Sc.
(Hons.), M.Sc., and Ph.D. in Electrical Power
and Machines from the Faculty of Engineer-
ing at Cairo University, Giza, Egypt, in 1992,
1997, and 2003, respectively. Currently, he is a
Lecturer in the Department of Electrical
Power and Machines with the Faculty of
Engineering, Cairo University. His areas of
research include electric machines, electric
drives systems, electromagnetism, and wind
energy systems.
Tamer Mamdouh Abdo received his B.Sc.
(Hons.) and M.Sc. in Electrical Power and
Machines Engineering from Cairo University,
Giza, Egypt, in 2004 and 2009, respectively.
His areas of research include electric
machines, electromagnetics and wind energy
systems.
Amr Amin Adly received the B.S. and M.S.
degrees from Cairo University, Egypt, and the
Ph.D. degree in electrical engineering from the
University of Maryland, College Park in 1992.
Since 1994, he has been a faculty member in
the Electrical Power and Machines Depart-
ment, Faculty of Engineering, Cairo Univer-
sity, and was promoted to a Full Professor in
2004. He also worked in the United States as a
Visiting Research Professor at the University
of Maryland, College Park, during the sum-
mers of 1996–2000. His research interests include electromagnetic field
computation, energy harvesting, modeling of superconducting and
complex magnetic materials.