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Published in IET Electric Power Applications
Received on 19th April 2012
Revised on 10th August 2012
Accepted on 19th September 2012
doi: 10.1049/iet-epa.2012.0129
ISSN 1751-8660
Abstract: Most of the induction motor (IM) fault detection schemes are based on one sensor with one detection logic which are
generally incapable of bringing out any consistent feature related to rotor misalignment. Moreover, these logics do not consider
simultaneously the asymmetric load condition with variable speed operation. In this study, a data fusion-based misalignment
related fault identication algorithm is presented, which isolates fault features from similar features generated because of other
operating conditions. In the proposed scheme, the feature vector is constructed by using signatures created from frequency-
domain characteristics obtained from stator vibration and line current measurements. Thereafter, the feature fusion technology,
by means of the weighted linear combination concept, is adopted to take advantage of the best features from both sensors and
to discern the pattern of misalignment with other signatures. The technique is validated experimentally on a 5.5 hp IM and
the results are presented.
Fig. 1 Different mechanical faults observed in medium size HSM motors because of high degree of rotor misalignment
a Shaft crack
b Bearing Cease
c Rotor rubbing
d Circlip opening
[9], the resultant air-gap ux density can be expressed as harmonic currents in the stator winding. The eccentricity
related harmonics present in motor current [9], can be
B(u, t) = Bms ,Vs cos ms u Vs t expressed as
ms ,Vs
(1)
fecc = (Krs R + Kd ) fr + 2Ksat p fs ) (2)
+ Bmr ,Vr cos mr u Vr t
mr ,Vr
where, fr and fs are rotor frequency (rps) and supply
where frequency. Replacing fr with ((1 s)/p)fs and rearranging
(2) gives
ms = Krs R + Kss S + Ks + Kd + 2Ksat p + kp
1s
Vs = Krs R + Kd )vr + 2Ksat v + v fecc = fr slot + Kd + 2Ksat fs (3)
p
mr = Krs R + Kss S + Ks + Kd + 2Ksat p + lp
where fecc and frslot are the eccentricity and slot harmonic
Vr = Krs R + Kd )vr + 2Ksat pv + sv related frequencies. Theoretically and experimentally, it has
been established in [5, 10] that under a mixed eccentricity
where Ks and Kd are the harmonic order related to static condition, side-band frequencies also appear near a
and dynamic eccentricity, Kss and Krs are the harmonic fundamental frequency.
order related to stator and rotor slot harmonics, Ksat is
the harmonic order related to saturation, R and S are f ecc| fund = fs + n fr|n=1,2,3,... (4)
the number of rotor and stator slots respectively, k and l are
stator space harmonic and rotor space harmonic components 2.2 Motor frame vibration analysis
respectively, s is the slip is the angular position of the
stator at time t, and r are the fundamental supply Many electrical and mechanical forces are present in IM that
frequency and rotor speed in rad/s, respectively. can cause vibrations [11]. The magnetic forces acting on the
The net air-gap ux density (1) because of stator and rotor stator of IMs because of the electromagnetic interaction
MMF, varies both in space and time. The time-dependent between the rotor and stator circuits, contributes to a great
harmonic ux components will produce corresponding extent to the generation of stator frame vibrations. The
Fig. 3 Typical load torque demand and corresponding motor current in 6-stand nishing mill of steel hot rolling process
X-axis is time in seconds, Y-axis (top plots) load torque in KNm and (bottom plots) motor current in Amps
WLC algorithm is shown in Fig. 4. The features considered in spectral components into a manageable number. A
the present work are listed here rule-based lter is proposed which, not only considers the
spectral components above a xed dB difference to the
1. Fourier features present in current and vibration signals, fundamental (50 dB), but also considers the dB difference
related to rotor eccentricity fault and asymmetric load of small components with respect to large components.
2. Motor shaft load and rpm The steps for adaptive threshold calculation are
3. Floor noise level
4. Strike rate of the presence of similar pattern of signature 1. Calculate mean of the feature set |jmf | = m jmf /M .
under same operating conditions 2. Identify components with magnitude less than |jmf |.
f
3. Compute mean of small components (|jsmall |) and mean
f
of remaining components (|jrest |).
f f
The different stages of the proposed system are discussed 4. Evaluate adaptive cutoff l f (= ((jsmall + jrest )/2),
here 50 dB).
5. Extract feature set f as large components from jmf with
magnitude > f
4.1 Data processing 6. If f is persistent for few (6 in this case) frames then
The acquired line current and stator frame vibration signals consider else ignore.
are ltered using a third-order Butterworth lter,
with cut-off frequency near the Nyquist frequency
( fcutoff 0.99 fnyquist or 495 Hz). This removes the 4.3 Feature fusion using WLC
switching frequency component of variable speed drive and To improve the fault identication rate, feature fusion by
also improves the signal-to-noise ratio. means of the WLC concept is adopted. The mathematical
Further signal processing is carried out, to eliminate the DC denition of WLC can be given by (5)
component which may appear during the low-speed operation
of the motor or from the sensors. DC levels for the signals are
n
estimated for each digitised frame using a Fourier transform. S= wi (dB)i (5)
F
The estimated DC level is XDC F
= X 0 where F signies the i=1
F
current frame of signal, X 0 is the non-sinusoidal component F where wi is the ith weight for ( fi)th characteristic frequency.
in the signal. The DC corrected frame is X F = (X F X DC ), (dB)i is corresponding dB value of signal. Weighted score
(S) for current (Sc) or vibration signal Sv. The characteristic
4.2 Spectral component extraction frequencies [7, 8, 11] of interest are listed in Table 1. All
the features appearing in column (3)* of Table 1(a) and in
Fast Fourier transform (FFT) is performed with Hanning column (3)*, (5)* and (6)* of Table 1(b) with mark are
window (50% overlapping) on X F . A normalised Fourier potential indicators for identifying the misalignment related
transform (X ) using (Welch) power spectral density (PSD)
f
faults. Weights of relative importance (i.e. more the weight
is calculated. A feature set jmf , (where m = 1, 2,) is more important the characteristic frequency) are assigned
created by detecting the frequency peaks in this normalised directly to each feature and a weighted map of features are
spectrum. constructed. The weight criteria for different combination of
It is proposed to remove small frequency peaks (less features are given in Table 2. The weights are divided
affecting) from the feature set jmf to reduce unmanageable into four categories. W = 0 (feature not to be considered),
Table 2 Weight factor for different features under different operating conditions
Characteristic frequencies in motor Characteristic frequencies in stator
current frame vibration
Loading condition Motor RPM fs + fr fs fr fs 2fr fs + 2fr 2fs 2fr 2fs + fr 2fs fr
low (030%) speed (<25%) 0.5 0.5 0.0 0.0 0.5 0.75 0.0 0.0
speed (2560%) 0.5 0.5 0.0 0.0 0.5 0.75 0.0 0.0
speed (>60%) 0.5 0.5 0.25 0.25 0.5 0.5 0.25 0.25
medium (3060%) speed (<25%) 0.5 0.5 0.25 0.25 0.5 0.75 0.25 0.25
speed (2560%) 0.25 0.25 0.25 0.25 0.5 0.75 0.25 0.25
speed (>60%) 0.25 0.25 0.25 0.25 0.5 0.5 0.5 0.5
normal (>60%) speed (<25%) 0.05 0.05 0.5 0.5 0.5 0.5 0.25 0.25
speed (2560%) 0.05 0.05 0.5 0.5 0.5 0.5 0.5 0.5
speed (>60%) 0.05 0.05 0.5 0.5 0.5 0.5 0.5 0.5
6 Results and analysis The effect of adaptive cut-off threshold on motor current
is illustrated in Fig. 7. With adaptive cut off threshold
Tests are conducted at different speeds by setting different the unwanted large spectral frequency peaks are reduced
stator supply frequencies through the drive. FFT is signicantly. This in turn reduces the dimensionality of
performed on vibration and current signals at different feature vectors, and makes detection logic more robust with
operating speeds and load conditions. reduced computational time.
The performance of the signal processing function is Figs. 8 and 9 show the low-frequency spectra of the motor
illustrated in Fig. 6. It may be observed (Fig. 6b) that, current and vibration of stator frame. The results are presented
because of poor signal strength, the side band frequencies here under three loading conditions and at different speeds 5,
are overshadowed by the low-frequency noise signal after 15 and 25 Hz. The points 1, 2 and 3 indicated on graph
performing a normal FFT. The desired signal components (Fig. 8), represent the frequencies fs, fs fr and fs + 2fr,
are enhanced using a rule-based lter and the characteristic respectively. Similarly, the marking on Fig. 9 indicates
features like side-band frequencies near fundamental different characteristic frequencies corresponding to fr; 2fr;
frequency are now discernible (Fig. 6c). 2fs; 2( fs fr).
Fig. 8 Frequency spectra of the stator current at different speeds and at different loads
a fs = 5 Hz; fr = 2.42 Hz
b fs = 15 Hz; fr = 7.0 Hz
c fs = 25 Hz; fr = 12.07 Hz
Fig. 9 Frequency spectra of the measured vibration at different speeds and at different loads
a fs = 5 Hz; fr = 2.42 Hz
b fs = 15 Hz; fr = 7.0 Hz
c fs = 25 Hz; fr = 12.07 Hz
The FFT and PSD analysis of the experimental data Comparative studies are also made for healthy motor,
presented here, reveals that motor with (mixed) eccentricity and motor loaded with an
asymmetric load under different operating speeds and motor
1. At low speed the observability of feature vectors are low. loading. One such result, is shown in Fig. 10. The analysis
However, two characteristic frequency components (for four gives an insight in helping us to distinguish
pole machines and at low speed assuming s 0), are fr = 0.5fs position-dependent load torque oscillation from rotor
and fr + fs = 1.5fs. These frequencies are present in the eccentricity faults. The most dominant features in motor
motor current under any operating condition. current resulting from a rotor eccentricity or load torque
2. Amplitude of fault frequency components are sensitive to oscillation are the side-band frequencies ( fecc = fs fr) near
load variation, however, these are not ideal under all loading fundamental [Fig. 10a(2) and 10a(3)]. The dominant
conditions. frequency in case of a healthy motor is only fs Fig. 10(a1).
3. The rotational frequency component fr and supply Other, higher-order side-band frequencies are only present
frequency component fs are clearly visible in all cases of in case of a faulty motor.
vibration and motor current signal. However, fr is more Similarly, in case of vibration signal, twice the line
prominent than fs in vibration signal. frequency vibration (2fs) component is present in both
Fig. 10 Appearance of characteristic frequencies for (1) the healthy motor (2) eccentric motor (3) healthy motor with asymmetric load
condition. fs = 25 Hz and fr = 11.9 Hz
a Spectral component of stator current space vector
b Spectral component of radial vibration signal space vector
eccentric and motor under oscillatory load (Fig. 10), whereas Table 2. The results demonstrate the effectiveness of the
one time rotational speed ( fr) dependent frequency is technique, the frequencies of higher importance have
prominent in case of eccentric motor only. Another become more prominent in comparison with less important
important point which was observed during experimentation features.
was that the amplitude of 2fs component is independent of After feature level fusion for current and vibration, the
load variation in case of an eccentric motor but is scores Sc and Sv are assigned true (T) or false (F) based on
dependent under an oscillatory load. Other, higher order whether the values are above the threshold (present
side-band frequency components are only observable in case it is 40 dB). From Figs. 11a and b, it is clear that in
case of eccentricity. case of a healthy motor the higher order side-band
Fig. 11 depicts the fault feature amplitude in motor current frequencies in both signals (current and vibration) will
and vibration after applying the WLC algorithm for the not be considered since their WLC values are much
characteristic frequencies as indicated in Tables 1. Fig. 11a below the threshold value whereas in case of motor
(1 and 2) show the spectral density plot for current and eccentricity, WLC values of these frequencies are much
vibration for healthy motor. For a motor with eccentricity higher and hence the frequencies are identied as fault
the same are indicated in Fig. 11b(1 and 2). Marks on the frequencies. The inuences of asymmetric load variation
graphs in Fig. 11(3 and 4) indicate the appearance of same on side-band frequency near fundamental (even these are
features in consecutive data frames (in this study six strong) are discriminated from the eccentric case, since
frames). Vertical lines in Fig. 11(5 and 6) indicate the the higher-order side-band frequencies are not present (or
weighted amplitude of characteristic frequency present in very low) in asymmetric load conditions [Figs. 11a(3)
the spectrum, which is computed using (5) and considering and b(3)]. The nal decision for eccentricity-related fault