online monitoring and analysis of induction ......n. hariharavarshan, jeyaram durga manian and r....
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International Journal of Electrical Engineering & Technology (IJEET) Volume 7, Issue 6, Nov–Dec, 2016, pp.36–54, Article ID: IJEET_07_06_004
Available online at
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ISSN Print: 0976-6545 and ISSN Online: 0976-6553
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ONLINE MONITORING AND ANALYSIS OF
INDUCTION MOTOR USING CURRENT SIGNATURE
ANALYSIS IMPLEMENTING WAVELET ANALYSIS
AND FFT ANALYSIS
N. Hariharavarshan, Jeyaram Durga Manian and R. MelvinaMinny
Electrical and Electronic Engineering, Panimalar Engineering College, Chennai, India
ABSTRACT
Three phase squirrel cage induction motors are widely used in industrial applications.Thus
fault occurring in these motors will adversely affect the Industrial products and increase the shut
down time. As time moves, the machine develops major faults and disturbs the production line
leading to major financial losses and production instability. In order to overcome these losses at
critical circumstances, the fault could be found out prior to it rather than becoming into a major
fault. Condition Monitoring System helps in predicting and identifying the pre fault condition in
faster and effective way, which prevents the unwanted breakdown timein working hours. Among the
various Condition Monitoring Systems such as thermal monitoring, vibration monitoring and so on
,Motor Current Signature Analysis (MCSA) is the best possible solution.As among all the available
solutions are intrusive in operation (need shutdown period for testing), maintenance of the
measuring equipment, bulk initial capital required, very high sensitivity and unreliable source with
even small unsuitable environmental factors, slower in fault detection .All the undesirable factors
of the other methods made MCSA an undisputable, viable, feasible ,reliable and best solution for
fault detection mechanism to be followed in even small scale industries. They are being followed in
many places often due to it’snon-intrusive approach to detect the fault, in addition a fast identifying
method using FFT analysis .Normally MCSA are performed with FFT analysis which is effective in
cases of constant load but as of today it is being an emergent problem to find fault in changing and
fluctuating load conditions, where FFT fails its viability and this condition made the solution to
choose wavelet analysis. In this paper, we have designed a complete3 phase induction motor with
matlab toolsand induced faults into the motor externally (by varying the input frequency) and
analysed the problem by using wavelet analysis. By analyzing the frequency spectrums of the stator
current, electrical torque and angular speed, we were able to determine the total harmonic
distortion for different faults and it will be produces clear explanation about the fault that is being
introduced into the machine which will finally pollute the power system by injecting harmful
harmonics into it.This method helps in envisioning the fault and thus helps in reducing the
occurrence of severe faults (Brinelling, Arcing, Rotor Failure etc.) in the motor. Thus it acts as an
important tool to protect machines from falling into unrepairable form. The MCSA model takes the
initial step in improving the efficiency of the system and the technique utilizes the result of spectral
analysis of stator current, torque and speed characteristics of the motor model.
Online Monitoring and Analysis of Induction Motor Using Current Signature Analysis Implementing Wavelet
Analysis and FFT Analysis
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Key words: MCSA (Motor Current Signature Analysis), FFT, Induction motor, wavelet.
Cite this Article: N. Hariharavarshan, Jeyaram Durga Manian, and R. MelvinaMinny. Online
Monitoring and Analysis of Induction Motor Using Current Signature Analysis Implementing
Wavelet Analysis and FFT Analysis. International Journal of Electrical Engineering &
Technology, 7(6), 2016, pp. 36–54.
http://www.iaeme.com/IJEET/issues.asp?JType=IJEET&VType=7&IType=6
1. INTRODUCTION
As the backbone of modern industry, induction motors are virtually used in every industry. Online fault
identification of induction motors are very important to ensure safe operation, timely maintenance,
increased operation reliability, and preventive rescue especially in high power applications. The induction
motor faults are generally classified as either mechanical or insulation system faults. An induction motor is
an AC electric motor in which the electric current in the rotor is needed to produce torque which is
obtained by electromagnetic induction produced from the magnetic field of the stator winding. An induction
motor therefore does not require mechanical commutation.
An induction motor's rotor can be either wound type or squirrel-cage; they both are the big
classifications between them in the view of rotor winding. Three phase induction motor or asynchronous
motors are widely used in industrial drives because they are rugged, reliable and have an economical
driving force. Common mechanical faults include rotor bar breakage, rotor end ring cracking, static and/or
dynamic air-gap irregularities, stator winding faults, bent shaft, misalignment, and bearing gearbox
failures. Statistical data indicates that the mechanical faults are responsible for more than 95% of all
failures. Single-phase induction motors are used extensively for smaller loads, such as household
appliances like fans, mixers and other house hold items. This makes induction motor an indisputable
competitor and indispensable position in the industries. The advantage of self-starting makes it more
efficient in the felid of electrical; this made the motor put into an immense research for improving its
efficiency and reducing its work spot failures.
The parameters that are considered in the construction of a induction motor is given in Table 1.These
parameters are made standard all over the construction process.
Table 1 Parameters of SCIM considered
Parameter Value
Power Rating of SCIM 40 KW
Frictional coefficient (B) 0.0100N-m/(rad/sec)
Moment of inertia (J) 1.662 kgm2
Mutual inductance (Lm) 0.040H
Rotor inductance (Lr) 0.043H
Poles (P) 2
Rotor resistance (Rr) 0.187Ω
Stator resistance (Rs) 0.087Ω
3 phase voltage(Vph) 375.588V
Peak voltage (Vm) 258.588V
N. Hariharavarshan, Jeyaram Durga Manian and R. MelvinaMinny
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2. CONSTRUCTION OF INDUCTION MOTOR SIMULINK MODEL
Figure 1 Generalized block representation of simulink system
The figure 1 is the overall block diagram that we followed to get the complete current spectrum that is
required to obtain the MCSA. The motor environment which is mentioned in the diagram is completely
implemented in the simulink using matlab and the formulae of designing induction motor .The formulae
have been implanted for each part of its construction. The total induction motor is distinguished into: • Electrical Subsystem model
• Torque Subsystem Model
• Mechanical subsystem model
• Stator Current Output Subsystem model
2.1. Electrical Subsystem Model
= 10−1/2√3 2 −1/2−√3 2 (1)
Equation (1):(Park’s Transformation, here we don’t need zero axis component and thus the equation is
simplified) is used to covert three phase voltageto two phase voltage
Where ,, and are the three-phase stator voltages, while and are the two-axis
components of the stator voltage vector . In the two-axis stator reference frame, the current equation of
an induction motor can be written as:
iiii = ! L0L#0
0L0L#L#0L0
0L#0L$%&
'()
× +,-
+-VVVV/0
−+,- R 0 0 000−P2 ω)L#
RP2 ω)0 L#0R−P2 ω)L
0P2Rω)L
/40 iiii
/440567
68 dτ
(2)
In the electrical model, the three-phase voltage [, ,] is the input and the current vector
[i, i, i,i] is the output vector. The rotor voltage vectors normally zero because of the short-circuited
cage rotor winding in the SCIM, i.e. Vdr=0 and Vqr=0.
Online Monitoring and Analysis of Induction Motor Using Current Signature Analysis Implementing Wavelet
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Figure 2 Park’s transform usage subsystem
In the figure 2 the inputs 1,2 represent Vdq and Vqs respectively. In electrical engineering, direct
quadrature zero(ordq0ordqo) transformation or zero–direct-quadrature (0dq) transformation is a
mathematical transformation that rotates the reference frame of three-phase systems in an effort to simplify
the analysis of three-phase circuits. This transform is referred to as Park’s transformation (Equation (1)).
2.2. Torque Subsystem Model
The electrical transient model in terms of voltages and currents can be given in matrix form as:
<==>??@AA
B = <==> C + EF GHF EFI GHFI−GHFEFI−(GH − G?)FI
C + EF(GH − G?)EFI FI −GHFI EFIC? + EF? (GH − G?)F?−(GH − G?)F? C? + EF?@AAB
<==>LLL?L?@AA
B
(3)
Where
S is the Laplace operator .The speed G?is considered constant for an infinite inertia load.
The electrical dynamics of the machine are given by a fourth-order linear system.
The speed can be related to torque as
MH = MN + O PQR (4)
GI = ST G? (5)
By substituting equation (4) in (5)
MH = MN + ST O PUR (6)
Where TLis the load torque.
The steady state equations can always be derived by substituting the time derivative components to
zero.
The steady state equations can be given as = CV + WGHX (7)
N. Hariharavarshan, Jeyaram Durga Manian and R. MelvinaMinny
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0 = YUZ V?+ WGHX? (8)
Where the complex vectors have been substituted by the rmsphasors. These equations satisfy the steady state
equivalent circuit if the parameter CI is neglected. The torque can be generally expressed in the vector form as:
MH = [S (TS)XI\\\\\] × V?\\\] (9)
Resolving the variables into ^H − _H components
MH = [S (TS)(XIL? − XIL?) (10)
The other forms of torque equations can be given as:
MH = [S (TS)(XIL − XIL) (11)
MH = [S (TS)(XL − XL) (12)
MH = [S (TS)FI(LL? − L?L) (13)
MH = [S (TS)(X?L? − X?L?) (14)
In the two-axis stator reference frame, the electromagnetic T is given by
M = TNQ[ (L?L − L?L) (15)
Figure 3 Torque and speed subsystem
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Figure 4 overall construction of induction motor
The figure 4 gives the overall construction of 3phaseinduction. The separate subsystems which are
explained in the earlier blocks, that constitute the induction motor. The variation of frequency is being
provided in the repeating frequency, this adds up as a external disturbance. The frequency that are
produced by certain faults are determined by experiments and formulae. The output is being obtained in
the workspace that is being further processed using wavelets (splitting the wave into smaller parts) and
FFT analysis.
This processing is very sensitive that, it will be able to find a smallest disturbance that is trying to
ingress into the system. This saves a lot of man, cost, and time waste and makes power system a proactive
area than reactive which normally it is. Further the faults that are being commonly found and not taken
timely reaction are jot down.
3. FAULT ANALYSIS
3.1. Introduction to Faults
The major faults in induction motor are due to stator, rotor and bearings. These faults can be classified as:
• Stator faults like shaft speed oscillation, Stator inter turn faults and grounded faults. The stator related faults
contribute upto 38% of total fault conditions.
• Rotor related faults like rotor asymmetry, rotor end ring faults and broken rotor bars. The rotor related
problems constitute to about 10 % of the faults occurring in the system.
• Bearing fault mainly includes the bearing ball failure. Here the racing of balls may lead to major damage of
induction motor. The bearing failure corresponds to 40% of the total failure.
3.2. Type of Faults
The induction motor is modeled using matlab and the frequency value for each fault is varied depending on
the formula. The frequency for healthy condition is 50 Hz. The frequency changes for faulty conditions.
The faulty conditions are broken rotor bar, bearing failure, shaft speed oscillation and rotor asymmetry.
Here the major faults are broken rotor bar and bearing failure. They are given as
3.3. Broken Rotor Bar
The broken rotor bar usually occurs mainly if there is a large load stress or subsequent heating on the rotor
bars. The uneven heating may lead to cracking and as the cracking develops it increases the resistance of
the rotor bar and hence it will cause increased current flow in the neighboring rotor bar and reduced current
flow in the broken rotor.
N. Hariharavarshan, Jeyaram Durga Manian and R. MelvinaMinny
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When the rotor is broken, the induction motor will not act at the fundamental frequency of the rotor but
it will operate at a new frequency which is given by H. The broken rotor bar can be distinguished by
presence of side bands. The new frequency is given by
H = ` a(bc? ± bH) e%$f g ± bh (16)
Where,
H=frequency for the broken rotor bar
`=supply frequency (50Hz)
Nr=rotor bars number=30
bH=eccentricity order number =0
s=slip per unit=0.4
Ns=supply frequency harmonic rank
P=number of pole pair
By using the values we have the values of H = 180.00kl
3.4. Bearing Failure
Bearing failure mainly occurs when a large load is applied on small area. This causes brinelling which may
lead to a permanent dent in the induction motor. The bearing failure can be found from the stator current
spectra. Since, the ball bearing will produce motions along with the stator. It produces a frequency greater
than the original frequency. The frequency variation depends on the bearing parameters and hence it varies
for each bearing. The frequency is given by
mn = ` ± b o,) (17)
o,p = mS ? a1 ± qrTr cos vh (18)
Where,
nb=number of balls
n=1,2,3,….
?=mechanical rotor speed in Hz(1380rpm to 23Hz)
BD=Ball diameter (0.6mm)
PD =bearing pitch diameter (0.31mm) v=contact angle=15.1degree
o,p=33.7Hz
By using the values we have the values of mn =252.23Hz
Online Monitoring and Analysis of Induction Motor Using Current Signature Analysis Implementing Wavelet
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3.5. Simulation Results for Various Fault C
The simulation results are further classified:
3.5.1. Healthy Motor Characteristics
The induction motor is modeled for 40KW, 2 Pole pair, and 460V Squirrel Cage Induction motor. The
healthy motor condition for 50Hz fundamental frequency is given by figure1
Figure
Figure
Figure
Online Monitoring and Analysis of Induction Motor Using Current Signature Analysis Implementing Wavelet
Analysis and FFT Analysis
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Simulation Results for Various Fault Conditions
results are further classified:
haracteristics
The induction motor is modeled for 40KW, 2 Pole pair, and 460V Squirrel Cage Induction motor. The
healthy motor condition for 50Hz fundamental frequency is given by figure1
Figure 5.a Speed characteristic of a healthy motor
ure 5.b.Torque Characteristics of healthy motor
ure 5.c. Stator current spectrum healthy motor
Online Monitoring and Analysis of Induction Motor Using Current Signature Analysis Implementing Wavelet
The induction motor is modeled for 40KW, 2 Pole pair, and 460V Squirrel Cage Induction motor. The
N. Hariharavarshan, Jeyaram Durga Manian and R. MelvinaMinny
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Figure 5.d.Quadrature Stator Current value healthy motor
All the above figures are related to the steady state 50Hz frequency. It is very clear from figure (a)
because the speed becomes constant after transient period of the induction motor.
From figure (c) the analyzer output rises peak only at its fundamental frequency (50Hz).From figure
(b) the torque characteristics is same as that of an induction motor. The Iqs is having a transient period of
4s and after that the exponential term gets cancelled, it can be seen from the fig (d).
3.5.2. The Simulation Results for Broken Rotor
When broken rotor bar occurs, the characteristics changes significantly and the value for the sideband
frequency level of this fault if found using Equation (16)
Figure 6.a Speed characteristics for broken rotor bars
Figure 6.b.Torque time charachteristics of a broken rotor
Online Monitoring and Analysis of Induction Motor Using Current Signature Analysis Implementing Wavelet
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Figure 6.c.Stator current spectrum of broken rotor
Figure 6.d. Quadrature stator current value of broken rotor
Broken rotor will drastically reduce the speed and the torque generated will be zero for ms depending
upon the no of rotor broken which is quite a serious problem that cannot be identified by other methods.
3.5.3. Simulation for Bearing failure
When bearing failure occurs, the frequency change of the spectrum depends on the dimensions of the
bearing and number of bearing which is considered. The frequency is given by (17) and (18).
Figure 7.a Speed characteristics for bearing failure
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Figure 7.b.Torque time charachteristics of a bearing failure
Figure 7.c. Stator current spectrum of bearing failure
Figure 7.d. Quadrature stator current value of bearing failure
The difference in all the spectrum are very prominently seen, this is because a failure of bearing will
heavy effect in the production of torque due to high friction opposing. And the spectrum peak varies quit
prominently
4. FFT AND WAVELET ANALYSIS
A Fast Fourier transform will identify the peak point and will give specific information about the output
waveform. It is very essential to identify the waveform distortion from the ideal waveform. This analysis
gives the peak location of distorted waveform and the harmonic order they create in the system. A FFT
analysis is just not enough to clearly identify the magnitude of the waveform ,so the mother wavelet is
Online Monitoring and Analysis of Induction Motor Using Current Signature Analysis Implementing Wavelet
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further divided into 6 child wavelets from mother wavelet, these child wavelets gives the possible small
peak achieved in each of the separated wavelet.
An FFT analysis allows to find the component of the frequency that disturbs output,but by doing this
we lose all control over the temporal spread.Whereas the original signal, when measured at a fixed time,
gives only absolute precision on the amplitude at that fixed time, but zero information about the frequency
spectrum of the signal. This makes wavelet analysis very pressing in this part so that we get the
characteristic of the parameter ω (which is the analogue of the frequency parameter k for the Fourier
transform), we can derive a characteristic frequency k(ω)and in the characteristic time t(ω) which makes it
a extraordinary perfection to the end result.
4.1. FFT Analysis
The spectrum analysis of the stator current, speed and torque will give the harmonic order. For healthy
condition the values are found with THD as 0.00 % as given in fig8.a, fig8.b and fig8.c respectively.
Figure 8.a. Healthy FFT analysis of Stator current
Figure.8.b.Healthy FFT analysis of speed
Figure 8.c.Healthy FFT analysis of Torque
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For the broken rotor by performing FFT analysis it could be found that the THD of order 8 occurs.
Figure 9.a.Brokenrotor FFT analysis of Statorcurrent
Figure 9.b.Brokenrotor FFT analysis of Speed
Figure 9.c. Brokenrotor FFT analysis of Torque
For bearing failure, the frequency is very high and the harmonic level is of the order 11 for stator
current
Figure 10.a. Bearing failure FFT analysis Stator current
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Figure 10.b. Bearing failure FFT analysis of Speed
Figure 10.c.Bearing failure FFT analysis torque
Table 2 FFT ANALYSIS THD COMPARISONS
S.No Parameters considered Healthy Broken Bars Bearing
Failure
1. THD for speed 0.00% 108.34% 102.27%
2. Fundamental for torque 106.3 1.214 2554
3. THD for torque 0.00% 585.25% 1419.74%
4. Fundamental for Is 262.8 3.09 6064
5. THD for Is 0.00% 1912.34% 6703.86%
6. Harmonic order of THD
Mechanical speed
1st
harmonic
order
8th order
harmonics
can be
noticed
11th order
harmonics
7. Harmonic order of THD
for Is
1st
harmonic
order
8th order
harmonics
can be
noticed
11th order
harmonics
8. Harmonic order of THD
for torque
1st
harmonic
order
8th order
harmonics
can be
noticed
11th order
harmonics
N. Hariharavarshan, Jeyaram Durga Manian and R. MelvinaMinny
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4.2. Wavelet Analysis Results
The wavelet analysis is done in matlab by programming and further decomposing into smaller wavelets of
spectrum. As the wavelet transformation is having an important requirement in the field wavelet
transformation is being applies in all the comparable parameters to find the prominent differences
compared to a healthy motor characteristics:
4.2.1. Healthy motor waveforms wavelet analysis
Healthy condition waveform for the motor when wavelet analysis is done for a frequency of 50Hz.this is
the fundamental frequency of a power system.
Figure 11.a.Waveforms of stator current, speed, torque in healthy condition
Figure 11.b.Wavelet decomposition of Stator current healthy condition
Figure 11.c.Wavelet decomposition of Torque in healthy condition
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Figure 11.d.Wavelet decomposition of speed in healthy condition
The above waveforms are the decomposition of mother wave form into child wavelet are clearly made
for study purpose.
4.2.2. Broken rotor bars wavelet Transform
Broken rotor is is another type of faults which is found in the induction motor very frequently the
fundamental frequency is not 50Hz but changes to 180Hz it can be calculated from Equation(16).
Figure 12.a.Waveforms of stator current, speed, torque in broken rotor bars
Figure 12.b.Wavelet decomposition of stator current waveform broken rotor bars
Figure 12.c.Wavelet decomposition of torque waveform of broken rotor bars
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Figure 12.d.Wavelet decomposition of speed waveform of a broken rotor bars
Bearing failure is is another type of faults which is found in the induction motor very frequently the
fundamental frequency is not 50Hz but changes to 252Hz it can be calculated from (2),(3)
Figure 13.a.Is, Speed and Torque waveforms of bearing failure
Figure 13.b.Wavelet decomposition of stator current of bearing failure
Figure 13.c. Wavelet decomposition of torque of bearing failure
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Figure 13.d.Wavelet decomposition of speed waveform of a bearing failed motor
Table 3 WAVELET ANALYSIS COMPARISONS
5. CONCLUSION
The results produced by approaching machines with these methods are very precise and the time for
identification of faults is not more than 10 s of occurring faults. In real work environment a fault finding
process is achieved with lower accuracy, though achieved the differentiation of faults and identification of
the intrusion depth of the fault in the system are not identified in a fine manner.
From table III it is tacit that the amount of energy spent recklessly, when a fault occurs. The faults
when left unidentified will slowly reduce the machine performance and will finally leads banishing of the
machine from the work environment .This makes the wastage of the life time of a machine. The table II
and table III remains console of the whole paper which precisely desiccates the fault levels identification
strategy.
REFERENCE
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S.No Parameters Healthy
condition
Broken
rotor bar
Bearing
Failure
1. Energy Stator
current
1.3899e+06
2.4784e+06
9.29e+05
2. Standard Deviation
Stator current
4.6970
2.4637
1.5717
3. Energy Torque
7.8176e+05
2.4238e+03
42.7357
4. Standard Deviation
Torque
6.6761
0.4801
0.0106
5. Energy Speed
5.1894e+07
1.8259e+06
1.8668e+07
6. Standard Deviation
Speed
12.3349
5.4466
7.9625
N. Hariharavarshan, Jeyaram Durga Manian and R. MelvinaMinny
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