FAULT D TESTING AND RESPONSES OF INDUCTION MOTOR …

لعلوم الأساسية والتطبيقية ا :مجلة الجامعة الأسمرية

2017يونيو (،1العدد )( 2)جلد الم

69

FAULT DIAGNOSIS, TESTING AND RESPONSES OF

INDUCTION MOTOR SYSTEMS

Moftah M. BinHasan1 and Ibrahim A. Farhat

2

1 Electrical and Computer Engineering Department, Faculty of Engineering, Almergib University

2 Electrical and Computer Engineering Department, Faculty of Engineering, Al-Asmarya University

ABSTRACT

Among the many great features of induction motors are their simplicity, reliability, efficiency

and high robustness. For these, they are extensively employed in various applications and

industrial fields. Nevertheless, motors, as it is the case for other appliances and equipment, are

exposed to various types of faults. Consequently, these faults must be monitored, classified and

diagnosed in order to prevent possible disastrous failures of the machine itself and the whole

system as well. This paper explores the various faults that motors are vulnerable to by performing

the appropriate tests. The results were obtained by collecting the different detected response

signals.

KEY WORDS: Fault Diagnosis, Motor Current Signature Analysis, Tree Phase Induction Motor.

1. INTRODUCTION

Induction motors are electromechanical elements that are widely utilized in various industrial

and operational systems. As a result, they are comprehensively vulnerable to different types of

faults. Therefore, exploring these faults and their consequences as well as proposing solutions for

their problematic issues are getting growing attention [1-4].



70

Faults associated with induction motors can be generally described as either internal or external.

In general, faults could be electrical or mechanical, and they can be categorized according to their

location as stator or rotor faults. Accordingly, rotor faults include all moving parts faults such as

those related to bearing and cooling elements [5]. Fig. 1 illustrates the classification of faults an

induction motor may be exposed to [6].



71

Motor Faults

Internal

Faults

Electrical Mechanical

External

Faults

Electrical Enviromental Mechanical

Magnetic Faults

Dielectric Failure

Rotor Bars Cracks

Bearing Faults

Parts Movements

Rotor Strikes

Transient Voltage

Unbalanes

Voltage Fluctuations

Magnetic Faults

Dielectric Failure

Dielectric Failure

Temrature Humidety

Cleanliness

Figure 1. Classification of motor faults.

Statistically, different motor fault types occur with various probability percentage. About 40% of

faults are associated with bearing failures, while nearly other 40% are stator faults and 10% are

rotor-linked faults as shown in Fig. 2 [6].



72

Figure 2. Motor fault occurrence probabilities.

Numerous research papers and studies have explored the methods implemented for fault

monitoring, detection and diagnosis. Comprehensive review of the methods applied for motor

fault diagnosis could be found in [1]. Typically, faults are diagnosed using expert signal

analyzing systems that analyze the fault signals obtained by various sensor units [1]. However, it

is commonly difficult or even impossible to interpret the information contained in a raw signal to

meaningful information by just looking at it. In addition, raw signals obtained from an instrument

measuring a physical process always contain noise that hampers the useful information contained.

40%

38%

10%

12%

Motor Fault Occurrence percentage

Bearing Faults

Stator Faults

Rotor Faults

Other Faults



73

The reminder of the paper is organized as follows: in section 2 the types of induction motor faults

are presented. In Section 3, the fault diagnosis methodology is briefly outlined. Results and

discussion are demonstrated in Section 4. The conclusion is drawn in Section 5.

2. FAULTS IN INDUCTION MOTORS

As mentioned, motor faults are categorized according to their location. In this section the

various types of motor faults are presented and explored.

2.1 Rotor Faults

Electrical and mechanical deficiencies can cause rotor faults. This may take place because of

thermal stress, overheated parts of the rotor. Torque changes and transient operation could also

result in fatigue stress and breaking or damaging the rotor bars. Air gap eccentricity, load

unbalance or shaft misalignment are among the many other fault causes [7, 8].

2.2 Bearing Faults

Faults of bearings are classified into two main groups. They could be local or distributed

deficiencies. Cracks of the rolling surfaces, for instance, are local faults while surface roughness

and off-size rolling elements as well as misalignment of races are considered distributed ones [9].

Bearing faults cause vibrations as a result of the flawed bearings. In order to specify the

characteristic frequencies accompanying the raceways and the balls or rollers, the dimensions of

the bearings and the machine rotational speed are utilized. A range of mechanical vibration

analysis methods is used to inspect these characteristic frequencies in order to determine the

condition of the bearing [1].



74

2.3 In-turn Stator Faults

Stator faults can take place as a result of various stressful operational conditions involving

electrical, mechanical, thermal, environmental everyday operational situations [10-12]. Stator

faults are, in fact, linked to its windings and include open circuit, phase-to-phase, coil-to-coil

turn-to-turn and coil-to-ground [13]. Fig. 3 shows the types of stator winding faults [14].

Figure 3. Types of stator winding faults.

Stator faults are divided into three main groups. The first is the frame defects which includes

those related to vibrations, circulating currents, earth faults and loss of coolants. The second is

the lamination-related faults such as core slackening and core hot spots. The last group covers all



75

of the stator winding faults including turn-to-turn faults, fretting of insulation, local damage to

insulation, damage to connectors, discharge erosion of insulation, displacement of conductors,

contamination of insulation by moisture, oil or dirt, cracking of insulation and other end winding

portion faults. It also includes all slot portion defects such as insulation fretting and displacement

of conductors [15].

2.4 Eccentricity Faults

Eccentricity faults of induction motors are caused by the uneven and dissimilar air gap between

stator and rotor [16]. Eccentricity of the air gap is commonly known as static, dynamic or mixed

while the inclined eccentricity is associated with the axial non uniformity of air gap [17, 18].

3. FAULT DIAGNOSIS

The data collected from the testing motor system considering different faults was presented

and investigated. The motor system was tested so that different signals were saved. Then the

system was forced to fail and retested. The work was done by collecting different sensed signals

of the motor under test while it has been exposed to different levels of loading. The tested motors

could be in a healthy or faulty condition. The sensed signals are current, voltage, accelerometer

signal, and speed.

Plots of the recorded output signals in time domain were illustrated and discussed. As the test rig

was well equipped, different tests were carried out and different signals were recorded for

different healthy and faulty cases of a set of four similar motors.



76

The following section covers the measured signals from the healthy and faulty motors. It includes

current, voltage speed, and accelerometer signal. The tests were carried out at 0, 25, 30, 35, 40,

and 50 Nm which is the rated motor load

4. STUDY RESULTS AND DISCUSSION

4.1 Rotor Fault

In this section, the effects of the fault due to the broken rotor bars on the motor under test’s

signals are illustrated. Figures plotted are for healthy and different degrees of fault severity at the

same level of loadings and for the same degree of fault at different load conditions.

Current Signals

As shown in the figures to come, it has been noticed that the direct effect of loading on the line

current of the motor drastically, the more load applied to the motor, the more current drawn as

shown in Fig. 4. The current is minimally and adversely affected by the severity of the rotor fault.



77

Figure 4. Line Current at Different Loads and Fault Severities.

Some signal distortion could be noticed, but the proper way to see the effect of the fault upon the

current and other signals in general, is to go through signal processing methods.

Fig. 5 shows that the severity of broken rotor bars has a direct effect on the motor currents. All

the plots were at the same loading, but due to the rotor breakage, the line currents have been

noticeably affected.

2.15 2.16 2.17 2.18 2.19 2.2 -30

-20

-10

0

10

20

Time (sec) C

urr

en

t (

Am

p)

1 Bar Broken Fault

i 0 Nm i 30 Nm i 40 Nm i 50 Nm

2.015 2.02 2.025 2.03 2.035 2.04 2.045 2.05 2.055

-30

-20

-10

0

10

20

Time (sec)

Cu

rren

t (A

mp

)

2 Bar Broken Fault




78

Figure 5. Effect of Broken Rotor Bars on Motor Line Current.

The more severe the fault, the lower the line current is. This could be linked to leakage happens

within the rotor circuit due to the broken bars. The increment of the rotor broken bars decreases

the induced rotor voltage and current.

Voltage Signals

The broken rotor bar fault has no apparent effect that can be noticed by scanning the voltage

figures. Fig. 6 illustrates the motor phase voltages for a faulty rotor at different loadings where no

change can be noticed at first look. Also voltages don not change for a fixed load for neither

healthy nor faulty rotor with different severities.

1.34 1.35 1.36 1.37 1.38 1.39

-20

-10

0

10

20

Time (sec)

Cur

rent

(A

mp)

1 BRB conditions @ 40 Nm

i1B2.5mm

i1B3.5mm

i1B4.5mm

i1B6mm

1.34 1.35 1.36 1.37 1.38 1.39

-20

-10

0

10

20

Time (sec)

Cur

rent

(A

mp)

Diff Rotor conditions @ 40 Nm

i2 BRB

Hlthy}

i1BRB4.5mm

i1BRB6mm



79

Figure 6. Effect of Broken Rotor Bars on Motor Voltages.

In general, for the normal viewer it could be said that while the motor voltage is noticeably

unaffected by rotor faults and loading, such effects are reflected in the current signal. The same

principle applies to healthy motors as in Fig. 7.

1.7 1.71 1.72 1.73 1.74-400

-300

-200

-100

0

100

200

300

400

Time (sec)

Vol

tage

1 Bar Broken Fault

V0 Nm

V30 Nm

V50 Nm

1.66 1.67 1.68 1.69 1.7 1.71-400

-300

-200

-100

0

100

200

300

400

Time (sec)

Volta

ge)

Diff Rotor conditions @ 40 Nm

V2 BRB

VHlthy

V1B4.5mm

V1B6mm

1.34 1.35 1.36 1.37 1.38 1.39

-20

-10

0

10

20

Time (sec)

Cur

rent

(A

mp)

Healthy Rotor

i0 Nm

i30 Nm

i40 Nm

i50 Nm

1.66 1.67 1.68 1.69 1.7 1.71-400

-300

-200

-100

0

100

200

300

400

Time (sec)

Vol

tage

)

Healthy Rotor

V0 Nm

V30 Nm

V40 Nm

V50 Nm



80

Figure 7. Healthy Motor Currents and Voltages at Different Loadings.

Speed Signals

The motor rotor speed is proportional to the load. As the load increases, the line current follows

and that leads to an increase in the speed. Fig. 8 illustrates the motor speed signal for different

loads and state conditions.

Figure 8. Effect of Rotor Fault on Motor Speed.

It should be noted that for the same load, the speed of a healthy rotor is much higher than that of

a defected one because the rotor induced voltage is linked to the density of the magnetic field

which has been lowered by the leakage occurring due to the rotor bar breakage.

Vibration Signals

The output signal amplitude of the accelerometer increases as the load (for the same type of fault)

and the fault together increase. A comparison of the signals of the healthy and faulty conditions at

the same loading is shown in Fig. 9.

2 2.0002 2.0004 2.0006 2.0008 2.001 2.0012 2.0014 2.0016 2.0018 2.002-15

-10

-5

0

5

10

Time (sec)

Roto

r Speed

Speed-2BRB/ Healthy @ 50 Nm

W2BRB

wH

2 2.005 2.01 2.015-0.5

0

0.5

Time (sec)

Roto

r Speed

Speed-2BRB @ Diff Loads

w0 Nm

w50 Nm



81

A rotor with broken bars causes the vibration signal amplitude to increase compared to a same

loaded healthy rotor. The vibration increases with the increase of the load for the faulty motor.

Figure 9. Vibration Signals at Various Healthy Conditions and Loads.

4.2 Bearing Fault

The bearing test is done in three phases, a healthy and two faulty situations. The faults seeded and

tested are abrasive or generalized roughness, and outer race defects. In the outer race, a test hole

is made with a rectangular shape of 1.5 mm width and 30 mm length.

Current Signals

For the healthy motor test, at no load, the current is at a peak of around 13 A. But when the motor

is loaded, the motor current withdrawal has increased as expected and it reached around 20 A

peak value as in Fig. 10 and Fig. 11.

The values of line currents are comparable regardless of the bearing state being healthy or not, for

the same load magnitudes. Also, for the same load, line current is preserved for both outer race

2 2.005 2.01 2.015 2.02 2.025 2.03 2.035 2.04 2.045 2.05-4

-3

-2

-1

0

1

2

3

4

Time (sec)

Voib

ration S

ignal

Vibration 2BRB/ Healthy @ 50 Nm

vib2BRB

vibHlthy

2 2.005 2.01 2.015 2.02 2.025 2.03 2.035 2.04 2.045 2.05-4

-3

-2

-1

0

1

2

3

4

Time (sec)

Vol

tage

)

Vibration 2BRB@ 0/50 Nm

Vib0Nm

Vib50Nm



82

and cage faults as in Fig. 10, where the proportioned relation of the load and line current is the

norm.

Figure 10. Motor Currents for Different Bearing Conditions.

Figure 11. Motor Current with Bearing Defects at Different Loads.

Vibration Signals

While studying bearing fault it worth looking at the vibration signal. The amplitude of the

recorded signal increases significantly when the motor is loaded as in Fig.12 and Fig.13.

1.555 1.56 1.565 1.57 1.575 1.58 1.585 1.59 1.595

-20

-10

0

10

20

Time (sec)

Cur

rent

(A

mp)

Healthy Bearings

i0 Nm

i40 Nm

i50 Nm

1.79 1.8 1.81 1.82 1.83 1.84 1.85

-20

-15

-10

-5

0

5

10

15

20

Time (sec)

Cur

rent

(A

mp)

Bearing Faults @ 40 Nm Loads

iCage Flt

iOuter Race Flt

iHealthy

2.18 2.2 2.22 2.24 2.26

-20

-10

0

10

20

Time (sec)

Curre

nt (

Amp)

Bearing with Cage Defect

i0 Nm

i40 Nm

i50 Nm

2.15 2.16 2.17 2.18 2.19 2.2 2.21-30

-20

-10

0

10

20

30

Time (sec)

Cur

rent

(Am

p)

Bearing with Outer Race Defect

i0 Nm

i40 Nm

i50 Nm



83

The vibration signal amplitude has obviously increased and the level of vibration is almost

doubled when the motor is 80% loaded compared to no load situation.

Figure 12. Vibration Signal of Healthy Motor at 0 and 40 Nm Loads.

Figure 13. Vibration Signals for Bearing Defects at Different Loads.

As shown in Fig. 13, the vibration signal of outer race defect has higher amplitude compared to

the abrasive or generalized defect if compared at the same loading condition. Though it is

expensive and not always easy to implement, vibration is the best medium to detect bearing

faults.

2 2.005 2.01 2.015 2.02 2.025 2.03 2.035 2.04 2.045 2.05-3

-2

-1

0

1

2

3

Time (sec)

Acc

ele

ration

Vibration Signals for Healthy Bearings

H0Nm

2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3-8

-6

-4

-2

0

2

4

6

8

Time (sec)Acc

ele

ratio

n

SI-IMCM-2103-BELT-M2-H-40Nm-20kHz-001.txt

Acc. Signal

2 2.005 2.01 2.015 2.02 2.025 2.03 2.035 2.04 2.045 2.05-2.5

-2

-1.5

-1

-0.5

0

0.5

1

1.5

2

2.5

Time (sec)

Acc

ele

ration

Vibration Signals for Diff Faults

Rghnss 40Nm

OutRce 40Nm

2 2.005 2.01 2.015 2.02 2.025 2.03 2.035 2.04 2.045 2.05-2.5

-2

-1.5

-1

-0.5

0

0.5

1

1.5

2

2.5

Time (sec)

Acc

ele

ration

Vibration Signals for Diff Faults

Roghns 0Nm

OutRce 0Nm



84

4.3 Inter-Turns Stator Fault

In this section, figures of motor currents during shorted turns fault testing are presented. The line

currents, as in Fig. 14 show a real linear change with the increment of the number of shorted

stator turns.

Figure 14. Number of Shorted Turns versus Phase Current.

The plots of Fig. 15 show that the change in current is not noticeable when the motor is loaded

with equal loadings even the shorted turns varied from 0 to 14 stator turns. In fact, there is a

change in some current parameters that can be calculated like negative sequence currents and

current imbalance values. Since the testing was done at 45 Nm load, there was no change

detected at glance in the current profile, but in fact, the RMS value of the currents changes with

the change of number of shorted turns.

RATED CURRENT

7.00

8.00

9.00

10.00

11.00

12.00

13.00

0 2 4 6 8 10 12 14

RM

S P

has

e C

urr

en

t (A

)

Number of Shorted Turns

Winding Current vs Shorted Turns

TEST 1



85

Figure 15. Motor Line Current of 0 and14 Shorted Turns.

4.4 Eccentricity Fault

The signals of two types of eccentricity are illustrated and compared to those of the healthy cases

in the following sections.

Voltage Responses

Fig. 16 shows the voltage time responses of the healthy and faulty motor with dynamic

eccentricity at different loading conditions.

Voltages have exhibited no changes for faulty motors compared to the healthy ones at different

levels of loadings.

2.23 2.24 2.25 2.26 2.27 2.28 2.29

-25

-20

-15

-10

-5

0

5

10

15

20

Time (sec)

Curr

ent

(A

mp

)

SI-IMCM-0903-M3-BELT-STATOR-0T-45Nm-20kHz-001.txt

i1

i2

i3

2.18 2.19 2.2 2.21 2.22 2.23 2.24

-30

-20

-10

0

10

20

Time (sec)

Cur

ren

t (

Am

p)

SI-IMCM-0903-M3-BELT-STATOR-14T-45Nm-20kHz-001.txt

i1

i2

i3



86

Figure 16. Motor Phase Voltages at Different Eccentricities and Loadings.

Eccentricity Current Signals

Fig. 17 illustrates the current responses for the healthy motor and for both static and dynamic

eccentricities with different loadings.

2 2.01 2.02 2.03 2.04 2.05 -30

-20

-10

0

10

20

30

Time (sec)

Cu

rren

t (A

)

Currents @ 40 Nm loading

i hlty i St.Ecc i Dy.Ecc

1.85 1.86 1.87 1.88 1.89

-40

-30

-20

-10

0

10

20

Time (sec)

Cu

rren

t (A

)

Healthy Motor- Eccty


2 2.01 2.02 2.03 2.04 2.05 -400

-300

-200

-100

0

100

200

300

400

Time (sec)

Vo

ltag

e (

V)

Dynamic Eccentricity

V 0 Nm

V 30 Nm

V 40 Nm

V 50 Nm

1.525 1.53 1.535 1.54 1.545 1.55 1.555

-400

-200

0

200

400

Time (sec)

Vo

ltag

e

(V)

Healthy Motor-

Eccentricityy

V 0 Nm

V 30 Nm

V 40 Nm

V 50 Nm



87

Figure 17. Motor Line Currents with Different Types of Eccentricity and Loads.

Eccentricity currents are not exceptional from their counterparts of other faults. They are only

affected by the loading amount not the fault type when initially looked at.

Vibration Signals

Fig. 18 shows different cases of vibration signals for two eccentricity types at different loading

conditions.

2 2.01 2.02 2.03 2.04 2.05 -30

-20

-10

0

10

20

30

Time (sec)



1.9 1.91 1.92 1.93 1.94 1.95

-30

-20

-10

0

10

20

30

Time (sec)

Curr

ent

(Am

p)

Static Eccty


Curr

ent

(Am

p)



88

Figure 18. Motor Accelerometer Output of Healthy and Eccentric Motor.

The amplitudes of the acceleration signal increases with the increment of the load applied to the

motor and it got even higher when the rotor gets eccentric dynamically compared to the static

eccentricity at the same load. The difference is noticeable between unloaded and fully loaded

motors signals especially for the dynamic eccentricity fault.

2 2.005 2.01 2.015 2.02 2.025 2.03 2.035 2.04 2.045 2.05 -8

-6

-4

-2

0

2

4

6

8

Time (sec)

Acc

ele

rom

et

er

Ou

tpu

t

Vib 0 Nm

Vib 50 Nm

1.735 1.74 1.745 1.75 1.755 1.76 1.765 1.77 1.775 1.78 -10

-5

0

5

10

Time (sec)

Acc

ele

rom

ete

r

Ou

tpu

t

Vib 50 Nm

1.555 1.56 1.565 1.57 1.575 1.58 1.585 1.59

-2

-1

0

1

2

Time (sec)


Vib 0 Nm

1.555 1.56 1.565 1.57 1.575 1.58 1.585 1.59

-2

-1

0

1

2

Time (sec)

Ac

ce

lero

me

ter

O/P

(m

/s


Vib 50 Nm

Ac

ce

lero

me

ter

O/P

Dynamic Eccentricity Static

Eccentricity



89

Speed Signals

The speed of the motor has a direct proportion with the load and line current. As the load of the

motor increases, an increase in the current follows which result in an increase in speed slip which

means a decrease of the rotor speed. By looking at Fig. 19, it is noticeable that the oscillation of

the rotor speed for a full loaded motor is higher compared to that of the non-loaded machine.

Figure 19. Speed Signals for Static and Dynamic Eccentricities at Different Loads

5. CONCLUSION

In this paper, the plots of some response signals that were recorded during the testing phase of

this research were presented for both cases of healthy and faulty motors. The motor current

signature analysis technique has been demonstrated as the most suitable and preferred method for

detection and diagnosis of the studied faults. Namely; broken rotor bars and inter-turn stator

shorts. For eccentricity and bearing faults, vibration is proven to be the most appropriate medium

for fault investigation.

2 2.005 2.01 2.015 2.02 2.025-2

-1.5

-1

-0.5

0

0.5

1

1.5

2

Time (sec)

Rot

or S

peed

St. Ecc @ Diff Loads

w0 Nm

w50 Nm

2 2.005 2.01 2.015 2.02 2.025-1

-0.5

0

0.5

1

1.5

Time (sec)

Rot

or S

peed


W0 Nm

W50 Nm



90

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FAULT D TESTING AND RESPONSES OF INDUCTION MOTOR …