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Detection of the Combination of Static and
Dynamic Air gap Eccentricity in 3-Phase
Induction Motors using Stator Current
Monitoring
Irahis Rodriguez, Roberto Alves
XVII International Conference on Electrical Machines ICEM 2006
      Abstract-- This paper deals with the application of Stator
Current Monitoring (CSA), for detection of the combination of
static and dynamic air gap eccentricity in 3-Phase induction
motors. Three-phase IM are the “workhorses” of industry and
are the most widely used electrical machines. In industrialized
nations, 70% of industrial processes use the induction motor. For
this reason, detection of incipient motor failures is very
important, thereby avoiding production lost and reducing
operational costs. The main idea of motor damage detection leads
with “motor variables, currents, flux, electric torque and power,
variations (in particular the spectrum) with respect to the normal
time-varying operating conditions of the motor”. MCSA is a
noninvasive on line monitoring technique to diagnose faults in
three-phase IM by differences detection between fault and
normal conditions, in current spectrum. Experimental tests were
realized in IM of small power, and the results will be validated in
later works with a representative quantity of motors.
      Index Terms—Static Eccentricity, dynamic eccentricity, motor
diagnostics, motor current signature analysis, frequency analysis.
1. NTRODUCTION
      Three-phase induction motors are the most robust of the
industry and are the electrical machines more widely used.
The induction motors are used in almost 70% of the industrial
processes. For this reason the importance of incipient motor
failures detection. The early motor failures detection and a
good prediction avoids the production loss and therefore the
economic losses. The main idea of motor damage detection
leads with "motor variables, currents, flux, electric torque and
power, variations (particularly the spectrum) with respect to
the normal time-varying operating conditions of the motor".
Motor Current Signature Analysis (MCSA) is a noninvasive,
on-line monitoring technique to diagnose faults in three-phase
induction motor drives, by differences detection between fault
and normal conditions in the current spectrum. Induction
Motors can operate with asymmetries, such as:
-     Stator windings failures (inter-turns or short circuits)
-     Broken rotor bars and end ring faults.
-     Mechanical failures (bearing damage, motor shaft failures
or air gap eccentricities).
      Asymmetric induction machine operation produces
asymmetric fluxes, unbalanced currents, pulsed torques and
losses increase. Final results can be efficiency reduction and
excessive temperature increase, which could lead to an early
isolation failure on the machine. Thus the detection of
incipient failures is very important to increase the time life of
the electrical machine. A failure in the electric motor can be
established by detecting some variations in the input currents
(stator currents), torque or flux compared with normal
operation variables [1]. Static and Dynamic Air gap
Eccentricity are produced by damage bearings and/or motor
shaft failures [2]. Actually bearings are one major cause of
failures in rotating machines [3] Using the monitoring of
noise, vibration and temperature is possible its detection. The
implementation of these measuring systems could be
expensive and probably only proves to be economical and
practical in the case of large motors or critical applications.
During the past 20 years, there has been a substantial amount
of research into the development of new condition monitoring
techniques for induction motors.
      One successful technique is the Motor Current Signature
Analysis (MCSA) [4]. This paper deal with the application of
MCSA of Static & Dynamic Air gap Eccentricity in Induction
Motors.
2. HEORETICAL ANALYSIS
      Eccentricity related faults:
      Machine eccentricity is the condition of unequal that exists
between the stator and rotor [5]. When eccentricity becomes
large, the resulting unbalanced radial forces (also known as
unbalanced magnetic pull or UMP) can cause stator to rotor rub, and this can result in the damage of the stator and rotor.
Rotor eccentricity in induction motors takes two forms, static
eccentricity (where the rotor is displaced from the stator bore
center but is still turning upon its own axis), and dynamic
eccentricity (where the rotor is still turning upon the stator
bore center but not on its own center). The causes of either
type of rotor eccentricity are many, worn bearings, a bent
rotor shaft, mechanical resonance at a critical speed, etc.
In reality both static and dynamic eccentricities tend to co-
exist. An inherent level of static eccentricity exists even in
newly manufactured machines due to manufacturing and
assembly method, as has been reported by Dorrell [6]. This
cause a steady unbalanced magnetic pull (UMP) in one
direction. With usage, this may lead to bent rotor shaft,
bearing wear and tear, etc. This might result in some degree of
dynamic eccentricity. Unless detected early, these effects may
snowball into stator to rotor rub causing a major breakdown of
the machine [7].
The presence of static and dynamic eccentricity can be
detected using MCSA [8]. The equation describing the
frequency components of interest is
Where n’= 0 in case of static eccentricity, and n’ = 1 y -1 in
case of dynamic eccentricity ( n’ is known as eccentricity
order), f is the fundamental supply frequency, R is the number
of rotor slots, s is the slip, p is the number of pole pairs, k is
is the order of the stator time harmonics
any integer, and n
i
that are present in the power supply driving the motor ( v =
±1, ±3, ±5, etc.). In case one of these harmonics is a multiple
of three, it may not exist theoretically in the line current of a
balanced three phase machine. However it has been shown by
Nandy [9], Ferrah [10] that only a particular combination of
machine poles and rotor slot number will give rise to static or
dynamic eccentricity related components. However, if both
static and dynamic eccentricities exist together, low frequency
components near the fundamental given by
can also be detected. Mixed eccentricity also gives rise to high
frequency components as described by [11]. Modeling based
approaches to detect eccentricity related components in line
current has been described in [12].
      A brief description of the acquisition data systems and of
the power equipments, it is described in the following section.
3. MONITORING OF THE INPUT CURRENT
      Instantaneous current monitoring implementation has been
shown in Fig. 1. It shows the induction motor, supply source,
load motor (DC generator), and the resistive load. To the left,
the data acquisition system can be observed, that is basically a
computer with an acquisition card. The acquisition card
converts stator current and voltage analog signals to digital
quantities.
      The circuit has been shown in Fig. 2, and the equipment
characteristics are:
-       M: IM, 2 HP, 220 V, 1680 rpm, Y, PF 0.76, 60 Hz;
-       G: DC Generator 2.2 kW, 230 V, 1800 RPM;
-       Load: Resistance Box TB 40, 3.3 kW;
-       R: Resistance Measurement includes seven shunts
resistances of 120 ohms, 1/4 watts each;
-       PT: Voltage Transformer 200/10.
-      CT: Current Transf. YEW, 10/1, 60 Hz, class 1;
      Input current, whose frequency spectrum is going to be
used to detect bearing failure, was obtained by dividing the
voltage in the resistance box connected in Current
Transformer 1 Ampere Side, into the value of the resistance
shunt.
      Data acquisition system has the following elements:
Signals conditioning equipment, Data acquisition card, and
software to drive the Data acquisition card. The acquisition
system is detailed in Fig. 3. The data acquisition target is AT-
MIO-16DE-10, with 16 single ended or 8 differential inputs,
12 resolution bits, Max. Sampling rate 100 KS/s, 32 digital
input-outputs, 2 analog outputs, 2 counter/timers 32 bits,
bipolar input range 10 volts. On the other hand, the language
program used was LabVIEW, version 5. LabVIEW contains a
comprehensive set of tools for acquiring, analyzing,
displaying, and storing data, besides is used to communicate
with hardware such as data acquisition, vision, and motion
control devices.
      The software LabVIEW was chosen to show the input
current. LabVIEW programs are called virtual instruments, or
VIs, because their appearance and operation imitate physical
instruments, such as Oscilloscopes and Multimeters. Lab
VIEW contains a comprehensive set of tools for acquiring,
analyzing, and storing data. Three virtual instruments were
designed in this work:
Virtual Instrument 1:
o       To Acquire and to save current and velocity; Virtual Instrument 2:
o       To read current and velocity; Virtual Instrument 3:
o       To read and to compare currents with healthy
motor and with static and/or dynamic eccentricity
air gap in induction motor.
4. EXPERIMENTAL RESULTS
      Experimental verification was carried out on a standard
220 V, 2.0 Kw, 4-pole cage induction motor connected to a 60
Hz supply. Bearing were damaged by grease contamination.
Tests were carried out at full rated voltage with varying
degrees of both static and dynamic eccentricity. Six load
points were used and the average taken of the acquisition of
20 spectrums of the line current for a same condition of load
(no variation in line current due to eccentricity was observed).
With the motor uncoupled the line current was 1.8 A, at a slip
0.03 the current was 3 A, and at full load (s = 0.05) the current
was 3.8 A.
A. Tests with the healthy motor.
      Tests were carried out with the next values:
      f1 = 60Hz
      n = 1
      n’= 0 for static eccentricity and 1 for dynamic eccentricity.
      p = 2
      R = 36
      ni = 1
      These tests showed the next results:
A1.-Tests with motor uncoupled, (s= 0.003594):
      In this case (fig. 4):
      1. - The frequency of static eccentricity was 1137.31 Hz, and the
magnitude for this frequency was 63.39 db.
      2. - The frequency of dynamic eccentricity (n’=1) was 1166.78 Hz,
and the magnitude for this frequency was 91.00 db.
      3. - The frequency of dynamic eccentricity (n’=1) was 1106.68 Hz,
and the magnitude for this frequency was 91.81 db.
Fig. 4 Tests with the healthy motor uncoupled.
A2.-Tests with s = 0.044082 ( 83.78% of load):
      In this case (fig. 5):
      1.- The frequency of static eccentricity was 1093.39 Hz, and the
magnitude for this frequency was 60.48 db.
      2.- The frequency of dynamic eccentricity (n’=1) was 1122.08 Hz,
and the magnitude for this frequency was 88.47 db.
      3.- The frequency of dynamic eccentricity (n’=1) was 1063.19 Hz,
and the magnitude for this frequency was 90.84 db.
Fig. 5 Tests with the healthy motor, s= 0.044082.
A3.- Tests with full load, (s = 0.052777):
      In this case (fig. 6):
      1. - The frequency of static eccentricity was 1084.09 Hz, and the
magnitude for this frequency was 64.92 db.
      2. - The frequency of dynamic eccentricity (n’=1) was 1112.28 Hz,
and the magnitude for this frequency was 91.84 db.
      3. - The frequency of dynamic eccentricity (n’=1) was 1055.19 Hz,
and the magnitude for this frequency was 89.90 db.
Fig. 6 Tests with the healthy motor, s= 0.052777.
B. - Tests with static and dynamic eccentricity air gap.
B1.-Tests with motor uncoupled (s=0.004491).
      In this case (fig. 7):
      1. - The frequency of static eccentricity was 1164.98 Hz, and the
magnitude for this frequency was 53.02 db.
      2. - The frequency of dynamic eccentricity (n’=1) was 1164.98 Hz,
and the magnitude for this frequency was 73.94 db.
      3. - The frequency of dynamic eccentricity (n’=1) was 1105.78 Hz,
and the magnitude for this frequency was 63.30 db.
Fig. 7 Tests with static and dynamic eccentricity air gap in motor uncoupled.
B2.-Tests with s = 0.046624 ( 83.78% of load):
      In this case (fig. 8):
      1. - The frequency of static eccentricity was 1090.29 Hz, and the
magnitude for this frequency was 55.69 db.
      2. - The frequency of dynamic eccentricity (n’=1) was 1118.88Hz,
and the magnitude for this frequency was 66.45 db.
      3. - The frequency of dynamic eccentricity (n’=1) was 1061.69 Hz,
and the magnitude for this frequency was 62.37 db.
Fig. 8 Tests with static and dynamic eccentricity air gap, s=0.046624.
B2.-Tests with s = 0.056508 ( full load):
      In this case (fig.9):
      1. - The frequency of static eccentricity was 1078.89 Hz, and the
magnitude for this frequency was 56.22 db.
      2. - The frequency of dynamic eccentricity (n’=1) was 1107.18Hz,
and the magnitude for this frequency was 66.81 db.
      3. - The frequency of dynamic eccentricity (n’=1) was 1050.59 Hz,
and the magnitude for this frequency was 60.71 db.
Fig. 9 Tests with static and dynamic eccentricity air gap, s=0.056508.
5. RESULTS
      The results show clearly that the magnitude for frequency
of static and dynamic eccentricity air gap grow with failure
Besides, the difference between magnitude for frequency of
static eccentricity and dynamic eccentricity is bigger with
damaged motor. Then, it’s possible to establish if the motor
has eccentricity problems analyzing the spectrum current.
      The Table 1 shows the values of differences between the
magnitude of the harmonics for frequencies of static and
dynamic eccentricity for considering good, acceptable or
unacceptable eccentricity. These ranks were obtained of the
analysis of the acquisitions.
Table 1: Motor Condition.
6. CONCLUSION
      This work describes a theoretical-experimental
methodology that has been implemented to determine
incipient failures in industrial induction motors.
      This paper shows the rank between the harmonic
magnitudes of the static and dynamic frequencies to
consider acceptable or unacceptable eccentricity,
independently of the load connected.
      The implemented experimental assembling and the data
acquisition system will allow the authors to continue this
investigation line.
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