Condition Monitoring and Faults Diagnosis of Induction Motors : Electrical Signature Analysis

171 Pages·2018·15.89 MB·English

by  Ibrahim

Condition Monitoring
and Faults Diagnosis
of Induction Motors
Electrical Signature Analysis
http://taylorandfrancis.com
Condition Monitoring
and Faults Diagnosis
of Induction Motors
Electrical Signature Analysis
Nordin Saad
Muhammad Irfan
Rosdiazli Ibrahim
CRC Press
Taylor & Francis Group
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Boca Raton, FL 33487-2742
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Library of Congress Cataloging‑in‑Publication Data
Names: Saad, Nordin, author. | Irfan, Muhammad, author. | Ibrahim, Rosdiazli, author.
Title: Condition monitoring and faults diagnosis of induction motors : electrical
signature analysis / Nordin Saad, Muhammad Irfan, and Rosdiazli Ibrahim.
Description: Boca Raton, FL : CRC Press/Taylor & Francis Group, 2018. | “A CRC title,
part of the Taylor & Francis imprint, a member of the Taylor & Francis Group, the
academic division of T&F Informa plc.” | Includes bibliographical references and index.
Identifiers: LCCN 2018010558| ISBN 9780815389958 (hardback : acid-free paper) |
ISBN 9781351172561 (ebook)
Subjects: LCSH: Electric motors, Induction--Testing.
Classification: LCC TK2785 .S23 2018 | DDC 621.46--dc23
LC record available at https://lccn.loc.gov/2018010558
Visit the Taylor & Francis Web site at
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and the CRC Press Web site at
http://www.crcpress.com
To my wife, Rozita; sons, Syahmi and Hakim; and daughters,
Liyana, Zawani, and Nadhirah, for the patience and inspiration
Nordin Saad
To my parents, Allah Ditta and Irshad BiBi; and grandparents,
Raheem Buksh and Janin BiBi, for the prayers and endless support
Muhammad Irfan
To my beloved wife and best friend, Lidia, and my princesses
Azra, Auni, Ahna, and Ayla, my love will always be with you
Rosdiazli Ibrahim
http://taylorandfrancis.com
Contents
Preface ......................................................................................................................xi
Authors ...................................................................................................................xv
List of Abbreviations .........................................................................................xvii
Nomenclatures ....................................................................................................xix
1. Introduction to Condition Monitoring of Electrical Machines ............1
1.1 Background ............................................................................................1
1.2 Condition Monitoring ..........................................................................4
1.3 Present Issues on CM ...........................................................................4
1.4 Outlines of the Book .............................................................................5
2. Background on Condition Monitoring Techniques ................................7
2.1 Introduction ...........................................................................................7
2.2 Structure of the Induction Motor ........................................................8
2.3 Various Faults Types of the Induction Motor ....................................9
2.3.1 Mechanical Defects ................................................................10
2.3.1.1 Bearings Defects .....................................................10
2.3.1.2 Air-Gap Eccentricity Defects ................................11
2.3.1.3 Abnormalities in Mechanical Transmission
System ......................................................................12
2.3.2 Electrical Defects ....................................................................13
2.3.2.1 Stator Winding Defects .........................................13
2.3.2.2 Rotor Defects ...........................................................14
2.4 Invasive Condition Monitoring Techniques....................................15
2.4.1 Acoustic Emission ..................................................................15
2.4.2 Thermal Monitoring ..............................................................16
2.4.3 Sound Monitoring ..................................................................17
2.4.4 Chemical Analysis .................................................................18
2.4.5 Vibration Analysis .................................................................18
2.5 Summary ..............................................................................................25
3. Noninvasive Methods for Motor Fault Diagnosis .................................27
3.1 Introduction .........................................................................................27
3.2 MCSA for Bearings Localized Faults ...............................................28
3.3 MCSA for Gear Faults .........................................................................31
3.4 IPA for Bearings Localized Faults ....................................................33
3.5 Impact of Environment Noise on MCSA and IPA-Based
Fault Detection.....................................................................................34
vii
viii Contents
3.6 PVA for Bearings Localized Faults ...................................................37
3.7 Noninvasive Methods for Diagnosis of Bearings Distributed
Faults .....................................................................................................39
3.8 Condition Monitoring Issues .............................................................40
3.9 Summary ..............................................................................................43
4. Design and Development of a Noninvasive Condition
Monitoring System .......................................................................................45
4.1 Introduction .........................................................................................45
4.2 Design and Development of Test Rig for Noninvasive
Condition Monitoring System ...........................................................46
4.2.1 Test Rig Base ...........................................................................48
4.2.2 Gear Box under Test ..............................................................48
4.2.2.1 Creation of Gear Defects .......................................49
4.2.2.2 Calculation of Gear Characteristic Defect
Frequencies ..............................................................50
4.2.3 Brake ........................................................................................52
4.2.4 Mechanical Coupling ............................................................52
4.2.5 Bearing under Test .................................................................52
4.2.5.1 Creation of Bearing Localized Defects................53
4.2.5.2 Calculation of Characteristic Defect
Frequencies Related to Bearing Localized
Defects .....................................................................54
4.2.6 Induction Motor Connection Scheme .................................55
4.2.7 DAQ and Processing ..............................................................56
4.3 Design of LabVIEW Program ............................................................58
4.4 Adaptive Threshold Design for IPA .................................................60
4.4.1 No-Load Conditions ..............................................................69
4.4.2 Medium-Load Conditions ....................................................69
4.4.3 Full-Load Conditions ............................................................70
4.5 Development of Noninvasive CM Method for Bearing
Distributed Faults ...............................................................................71
4.6 Summary ..............................................................................................76
5. Faults Analysis and Evaluations via IPA and PVA Methods ..............77
5.1 Introduction .........................................................................................77
5.2 Analysis of Gear Faults ......................................................................78
5.3 Analysis of Bearing Localized Faults ...............................................88
5.3.1 Analysis of Bearings Outer Race Defects ...........................88
5.3.2 Analysis of Bearing Inner Race Defects .............................97
5.3.3 Threshold Design for Variable Frequency Drive
(VFD) Operation of the Motor ............................................101
5.4 Comparison of the Proposed Fault Diagnosis Scheme
with previously used Schemes ........................................................105
Contents ix
5.5 Park Vector Analysis for the Diagnosis of Mechanical Faults
in Induction Motor ............................................................................112
5.5.1 Park Vector Analysis of Gear Defects ...............................112
5.5.2 Park Vector Analysis of Bearing Localized Defects .......112
5.5.3 Park Vector Analysis of Bearing Distributed Defects ....112
5.6 Analysis of IPA Technique ...............................................................121
5.7 Summary ............................................................................................122
6. Summary on Noninvasive Electrical Signature Analysis
Methods: IPA and PVA ..............................................................................123
6.1 Introduction .......................................................................................123
6.2 Overview of Noninvasive Faults Detection Methods .................124
6.3 Highlights of the Book .....................................................................127
6.4 Directions for Future Work .............................................................128
References ...........................................................................................................131
Index .....................................................................................................................147