Fault Diagnosis of Induction Machine for Rotor Cage Damage Using MCSA for Industrial Application

Abstract

The induction machine plays a vital role in industries. Induction machine failure causes significant process delays, higher maintenance expenses, and income loss. The machine’s predictive maintenance becomes crucial to find the primary cause of the defect. This paper focuses on the experimental results of induction machines used in the cement industry. Motor Current Signature Analysis is used to analyze the condition of rotor bars due to distorted input supply causing harmonics. The significance of this test is to determine the primary cause of the unexpected failure. The experimental results of the machine reveal distorted input with harmonics resulting in torque ripples. This might lead to broken rotor bars in the rotor cage with sidebands resulting in poor efficiency of the machine. Motor Current Signature Analysis predicts the lifespan of the machine to avoid unexpected failure. The Finite Element Method is used to design the machine for conditions one, two adjacent, and two non-adjacent broken rotor bars to observe the dynamics of rotor bar currents with numerical results. After a substantial overhaul of the machine, the proposed method is again performed, resulting in improved machine efficiency of 88.83%.

Keywords:

• induction machine
• broken rotor bars
• motor current signature analysis
• fast fourier transform
• finite element method
• lower sideband
• upper sideband

ACKNOWLEDGMENT

The authors would like to express their gratitude to “Flamboyant Solutions” and “Vignan’s Institute of Engineering for Women” for their valuable advice and assistance in performing the experimental work.

Disclosure Statement

No potential conflict of interest was reported by the authors.

Additional information

Notes on contributors

Kapu V Sri Ram Prasad

Kapu V Sri Ram Prasad received his B. E degree in Electrical and Electronics Engineering from Andhra University, Andhra Pradesh, and M. Tech degree in Power & Industrial Drives from Jawaharlal Nehru Technological University Kakinada, Andhra Pradesh, India in 2007 and 2013 receptively, and the Ph. D. degree in the Department of Electrical Engineering from the National Institute of Technology, Raipur. His research interest includes vibration control, condition monitoring, speed and torque control, fault detection of stator windings, rotor bars, and diagnosis of electrical machines for industrial applications.

Varsha Singh

Varsha Singh received B. E degree in Electrical Engineering from Government Engineering College, Bilaspur, and M. Tech degree in Computer Technology from N.I.T Raipur (Government Engineering College, Raipur), Chhatisgarh, and a Ph. D. in Electrical Engineering from N.I.T Raipur, India. Dr. Varsha Singh joined the National Institute of Technology, Raipur, India in 2009. Her research of interest is Vibration Control in electrical machines, Multilevel Inverters, Optimization methods in Power Electronics, and the Application of soft computing techniques in Electrical Systems for power quality improvement. AI techniques in computer Networks. She has published more than 20 papers in reputed journals and more than 30 papers at International Conferences.