Bearing Faults Detection in Induction Machines
Based on Statistical Processing
of the Stray Fluxes Measurements
Ciprian Harlişca, Loránd Szabó, Lucia Frosini, Andrea Albini
Φ
Abstract -- Frequent defects of induction machines are due
to diverse bearing faults. The detection of such faults in their
incipient phase can decisively contribute to the prevention of
unplanned breakdowns in industrial plants. In this paper the
detection of three types of bearing faults by means of statistical
processing of the stray fluxes measurements is detailed. The
developed noninvasive method requires only both simple probes
and easy computations. Numerous measurements had been
performed for all the combinations of bearing faults, loads and
stray flux probes taken into study. All the results emphasized
the effectiveness of the applied simple fault diagnosis method.
Index Terms--ac machines, ball bearings, electric machines,
fault detection, fault diagnosis, induction motors, rotating
machines.
I. INTRODUCTION
E lectrical machines with small faults can still work, but
these faults will evolve in time and they may cause a
E complete breakdown. Preventive measures should be
taken in order to protect the machines.
Faults can occur in any part of the machine. These can be
of electrical or mechanical origin. The main electrical faults
can be in the stator and rotor windings (or cage) [1], [2].
Mechanical faults include bearing faults, air-gap eccentricity,
gearbox faults, misalignments, etc. The most of the failures
(about 40%) are related to the bearings [3]. The bearing
faults do not cause immediate breakdown, but they evolve in
time until they produce a critical failure of the machine.
Unfortunately these failures finally results both in costly
repair costs and long downtimes.
The bearings faults can be caused by material fatigue,
overheating, harsh environments, inadequate storage,
contamination, corrosion, wrong handling and installation,
unbalanced loads, bearing currents, etc. [4]. However the
main cause of their failure is due to their poor lubrication,
which can be easily avoided by a correct maintenance plan.
Φ
This paper was supported by the project "Improvement of the doctoral
studies quality in engineering science for development of the knowledge
based society-QDOC" contract no. POSDRU/107/1.5/S/78534, project
co-funded by the European Social Fund through the Sectorial Operational
Program Human Resources 2007-2013.
C. Harlişca and L. Szabó are with Department of Electrical Machines
and Drives, Technical University of Cluj-Napoca, Romania (e-mails:
Ciprian.Harlisca@mae.utcluj.ro, Lorand.Szabo@emd.utcluj.ro).
L. Frosini and A. Albini are with Department of Electrical, Computer
and Biomedical Engineering, University of Pavia, Italy (e-mails:
lucia@unipv.it, andrea.albini@unipv.it).
978-1-4799-0025-1/13/$31.00 ©2013 IEEE
470
In the literature the bearing faults are classified according
to:
• the location of the fault: inner race, outer race, balls,
and cage;
• the fault signature: single-point defects and
generalized roughness.
Generalized roughness faults are the most frequent causes
of bearing failures. They usually occur in industrial
environment due to various mechanical causes which lead to
a faster wear of the components of the bearing, especially of
the raceways and balls. Such faults can be easily determined
because the bearing spins roughly or difficultly.
The detection of single-point bearing defects is more
difficult. If a moving component passes over a defected
surface in the bearing, it creates a succession of oscillations
which repeat with each pass over the damaged area [5], [6].
The repetition frequency of the impact depends on the
position of the fault within the bearing and has an indirect
impact on the current, magnetic flux, noise and vibration of
the machine.
In this paper the detection of three types of single-point
bearing faults by means of statistical processing of the stray
fluxes measurements is presented. The developed
noninvasive method requires only simple, even hand-made,
magnetic flux probes and some easy computation steps.
II. BEARING FAULT DETECTION TECHNIQUES
Upon performing a literature survey on the bearing fault
detection techniques it can be stated that a huge number of
methods are proposed.
A significant part of the papers are dealing with the
rolling bearings fault detection based on analyzing the stator
current and the vibration of the electrical machines [7].
These methods essentially are based on finding some
well-defined specific fault frequency components in the
spectrum of the current or vibration signals [8], [9].
Unfortunately vibration based monitoring techniques
require expensive precise vibration sensors and special
equipment. They also need direct access to the machine
under testing, which is not always possible in industrial
environment. On the other hand current monitoring requires
only simple current sensors [10]. The current monitoring
based techniques can be used to detect a large number of
other faults, too: broken rotor bars, shorted windings, air-gap
eccentricity [11], load faults, etc.
 Several research teams studied the detection of bearing
faults in electrical machines by using the stray flux around
the motor [12], [13]. The stray flux of an electric machine is
the magnetic flux that radiates outside the housing of the
machine. It is residual and undesirable, since it is not
participating in the torque generation [14].
The stray flux detection used in electrical machines fault
diagnosis is applied since about 30 years as an effective
technique for noninvasive diagnosis since the sensor can be
outside the machine without being necessary to measure
voltage, current or other electric or non-electric quantities
[15].
This method can be applied for detecting also other
electrical machine faults, as stator winding faults [16], rotor
defects [17] or voltage source dissymmetry [18].
Also another diagnosis method, the Park's Vector
Approach (PVA) is frequently used in detecting bearing
faults [19], [20].
In the last years several artificial intelligence (AI) based
bearing fault detection methods were developed [21]. The
most significant results were obtained by using artificial
neural networks (ANNs) [22], fuzzy logic [23], Support
Vector Machine (SVM) approach [24], particle swarm
optimization (PSO) [25], Hilbert-based bispectral analysis
approach [26], etc.
Several other fault detection methods are based on
processing the measured signals by means of the wavelet
transform [27], [28].
III. THE EXPERIMENTAL SETUP
The test bench for performing the experimental study was
built up in the Laboratory of Electric Drives of University of
Pavia, Italy (see Fig. 1).
Fig. 1. The experimental setup
The grid connected three-phase 2445T4050 type (FIR
Elettromeccanica S.R.L) induction machine has the
following rated data: power 2.2 kW, current 8.7 / 5 A, speed
2800 r/min.
The induction machine has two NSK 6205Z type rolling
ball bearings with nine balls, which are lubricated with
471
grease.
The induction machine is joined with a magnetic powder
brake of 5 kW and 100 N·m through an elastic couple. The
load can be set and measured by using the control unit of the
brake.
The standard measurements (of the RMS values of the
currents, voltages and active power) were performed via a
three phase power meter. The speed was measured with a
mechanical tachometer. For the phase current measurements
a simple Hall-effect based current probe was used.
For the specific stray flux measurements two magnetic
flux sensors were applied (see Fig. 3):
• a hand-made flux probe consisting of a semicircular
ferrite core with a 44 mm outer and a 40 mm inner
diameter. The ferrite core is wound with 300 turns of
enameled copper of 0.112 mm diameter [13].
• an industrial one, of M-343F-1204 type, produced by
Emerson. It has a circular form and consists of several
turns wound around an air-core. This probe can be
used to measure the leakage axial flux and it is similar
to most of the flux sensors cited in the literature, e.g.
[29].
a) hand made
b) commercial (Emerson)
Fig. 2. The applied flux probes
For a greater effectiveness of the measurements a first
order low pass RC filter (R = 1 kΩ, C = 82 F and a cut-off
frequency of 1942 Hz) was connected to each of the probes
[30].
The flux and current probes were connected to a portable
National Instruments data acquisition board and to a personal
computer with NI LabVIEW software. The used data
acquisition board is a NI USB 6212 type with 16 analog
inputs, 16 bit resolution, an input range of ±10 V and a bus-
powered USB for high mobility. The data acquisition was
controlled through a special created virtual instrument, which
allowed the simultaneous data acquisition from all the
connected probes.

IV. THE PERFORMED MEASUREMENTS

The current probe was placed on one of the phases and
the flux probes were positioned around the induction
machine in various places. The hand-made flux probe was
placed in three different locations around the housing of the a) hole in the outer race
machine in order to measure the axial body flux, the radial
flux on the end winding and the radial body flux,
respectively, as it is shown in Fig. 3a ,b and c. The Emerson
flux probe was positioned outside the fan end of the
induction machine, with its axis coincident with the shaft
axis, as shown in Fig. 3d.

b) deformation of the seal

Fig. 5. The faulted bearings
The induction machine was tested in its healthy condition
and having one of its bearings substituted by a faulty one.
For each machine condition the motor was tested at no-load,
at 50% of the rated load and at the rated load. Exceptionally
when the machine was tested with a cracked bearing, the full
load condition was not possible to be achieved due to very
a) axial body flux b) radial flux on the end-winding strong vibrations of the machine which could cause the
destruction of the machine.
During all the measurements performed 500,000 samples
were acquired at 10 kHz sampling frequency. For each set of
measurements ten consecutive acquisitions were collected,
with an acquisition time of 50 seconds each.

V. THE STATISTICAL DATA PROCESSING

After finishing the measurements all the saved data
acquisitions were processed via FFT in order to obtain the
c) radial body flux d) axial flux
harmonic spectrum of the signal. Here, in Fig. 6, only a
Fig. 3. Positions of the flux probes
for measuring different stray fluxes
single result set of the spectrum analysis is given.
Healthy
Three bearing faults were experimentally simulated and 0
Power density [dB]

studied [9]: −20

• crack in the outer race, similar to a fault caused by −40

excessive wear (Fig. 4); −60

• hole in the outer race (Fig. 5a); −80

−100
• deformation of the seal (Fig. 5b).
0 200 400 600 800 1000

Bearing fault
0
Power density [dB]

−20
−40
−60
−80
−100
0 200 400 600 800 1000
Frequency [Hz]

Fig. 6. The power density of the radial flux on the end-winding

Fig. 4. The faulted bearing for the healthy machine and that with a hole in the outer race
crack in the outer race of one of its bearing at 50% of the rated load

472
 As it can be seen, several frequency components (mainly
very close to the integer multiples of the fundamental)
indicating a bearing fault can be clearly distinguished in the
figure.
TABLE I
RESULTS FOR DAMAGED BEARING SEAL CONDITION
AT 50% OF THE RATED LOAD OBTAINED BY MEANS OF MEASURING
THE RADIAL FLUX ON THE END-WINDING

∆>2s

∆>5s
The implementation of the proposed statistical method

[Hz]

[dB]

[dB]

∆>s
mh

mf
∆ s

f
follows the subsequent steps [30]:
• each integer multiple of the fundamental, between 100 100 -40.74 -47.61 6.87 2.32
and 1000 Hz, is normalized with respect to the 50 Hz 150 -15.09 -14.03 -1.06 2.39
fundamental, as to be set at 0 dB. Only these harmonic 200 -48.89 -49.68 0.79 1.98
components were taken into study, since they do not 250 -13.49 -16.11 2.61 1.63
depend on the specific parameters of the machines 300 -48.33 -52.11 3.78 2.13
(e.g. number of rotor slots); 350 -24.90 -28.72 3.81 1.38
• for every harmonic component taken into account a 400 -62.99 -69.85 6.86 1.98
mean value of the ten acquisitions is computed, for 450 -35.63 -42.69 7.07 1.99
both the healthy and the faulty condition of the 500 -59.40 -72.00 12.60 1.93
550 -40.21 -51.32 11.11 2.22
machine (mh, mf, respectively);
600 -67.00 -74.77 7.77 1.87
• the difference of the mean values mentioned above
650 -47.30 -65.12 17.82 1.91
(d = mh - mf) is calculated; 700 -66.26 -73.82 7.55 2.05
• in order to evaluate the diagnostic content of the 750 -66.25 -66.61 0.35 1.43
processed data, the absolute value of the difference 800 -67.79 -71.77 3.99 1.22
(∆=|d|) is compared with the standard deviation (s) of 850 -46.63 -64.74 18.11 1.94
the harmonics in the case of the healthy motor. 900 -68.02 -73.19 5.17 1.13
Based on this comparison, three levels of fault 950 -60.44 -72.81 12.37 2.34
significance were considered [30]: 1000 -67.45 -74.54 7.09 1.62
• if ∆ > s, the level of significance is low ( );
As it can be seen in the table several harmonic
• if ∆ > 2s it is medium ( ); components indicate clearly the damaged bearing of the
• if ∆ > 5s it is high ( ). induction machine in study.
If these conditions are not fulfilled an incipient bearing
failure is impossible to be detected by means of this method. TABLE II
RESULTS FOR DAMAGED BEARING SEAL CONDITION
The proposed bearing faults detection method based on AT THE RATED LOAD OBTAINED BY MEANS OF MEASURING
statistical computations hopefully is really applicable in THE RADIAL FLUX ON THE END-WINDING
industrial environment as a truly accurate and robust fault

∆>2s

∆>5s
[Hz]

[dB]

[dB]

indicator.

∆>s
mh

mf

∆ s
f

The effectiveness of the proposed statistical computations

based method was studied for 20 cases, for all the 100 -46.47 -52.45 5.98 1.45
combinations of three bearing faults (crack in the outer race, 150 -20.64 -18.23 -2.41 1.47
hole in the outer race and deformation of the seal), three 200 -52.49 -57.87 5.37 1.17
loads (no-load, 50% of the rated load and the rated load) and 250 -19.98 -21.88 1.90 1.66
300 -52.81 -61.97 9.16 1.14
the two stray flux probes in the positions taken into study
350 -29.62 -31.90 2.29 1.49
(given in Fig. 3 ). From the huge amount of result only four
400 -67.79 -68.89 1.10 1.51
can be given here, those considered the most significant
450 -41.99 -44.28 2.29 2.42
ones.
500 -62.89 -76.00 13.10 2.25
In the following tables, for each experimental case, the
550 -44.26 -50.03 5.78 6.57
mean values of the logarithmic power spectral density for the 600 -72.70 -77.78 5.07 2.67
healthy and faulty machine, their difference, the standard 650 -54.61 -57.21 2.60 5.83
deviation, respectively the significance level of the 700 -70.77 -78.57 7.81 2.10
diagnostic index for all the frequency components taken into 750 -63.48 -61.66 -1.82 6.12
study between 100 and 1000 Hz at a 50 Hz step are all given. 800 -73.34 -77.19 3.86 2.21
850 -59.28 -61.37 2.10 1.94
900 -72.77 -79.16 6.39 2.11
950 -64.67 -64.36 -0.31 3.09
1000 -73.39 -78.61 5.22 1.26

473
 TABLE III The detection method based on measuring the radial flux
RESULTS FOR DAMAGED BEARING SEAL CONDITION
AT THE RATED LOAD OBTAINED BY MEANS OF MEASURING
body flux at the end windings can be also used to detect
THE AXIAL BODY FLUX outer bearing faults, as a crack in the outer race (see
Table IV).

∆>2s

∆>5s
[dB]

[dB]

∆>s
mh

mf
s
[Hz]

∆
VI. CONCLUSIONS
f

100 -45.12 -49.86 4.75 1.96 Bearing faults are one of the most frequent defects of
150 -25.24 -24.81 -0.42 1.69 induction machines. Therefore the detection of such faults
200 -57.03 -58.42 1.39 2.38 already in their incipient phase is quite important in the
250 -16.48 -18.74 2.26 1.97 industrial environment.
300 -74.77 -72.39 -2.38 2.11 In the paper a noninvasive bearing fault detection
350 -33.21 -37.68 4.47 1.69
methodology is presented, which involves simple
400 -63.85 -73.85 9.99 2.80
measurements of the stray flux around the machine by means
450 -58.47 -64.03 5.56 2.06
of different flux probes in different positions. It was proven
500 -65.91 -74.80 8.90 2.26
that by applying the method three basic bearing faults types
550 -44.08 -55.76 11.68 2.12
can be detected by simple measurements and computations.
600 -69.87 -79.11 9.23 1.41
650 -56.01 -63.51 7.49 2.06
The most effective detection was performed by measuring
700 -68.46 -79.50 11.04 3.30
the radial stray flux of the induction machine's end-winding
750 -58.28 -67.99 9.71 2.95 by using the hand-made flux probe. Insignificant results were
800 -75.36 -77.74 2.39 2.08 obtained by measuring the axial stray flux of the machine via
850 -53.45 -68.27 14.81 3.59 the Emerson flux probe.
900 -70.38 -80.68 10.30 3.26 Also the stator currents were measured and processed in
950 -66.19 -79.17 12.98 3.99 the frame of the study [30]. However the diagnostic content
1000 -72.97 -78.65 5.68 2.08 given by this parameter was less significant with respect to
the information given by the stray flux, therefore they were
Upon the results given in Table III it can be stated that not detailed in the paper.
also the axial body flux signals of the induction machine can The tests performed at different loads have shown
be used in fault detection, in a similar way as the radial flux noteworthy similarities, which means that the developed fault
on the end-windings. detection method can be a useful tool regardless of the tested
machine loading.
TABLE IV
RESULTS FOR DAMAGED OUTER BEARING RACE CONDITION The fault detection method detailed in the paper seems to
AT THE RATED LOAD OBTAINED BY MEANS OF MEASURING be quite effective. Moreover, the applied hand-made
THE RADIAL BODY FLUX
magnetic flux probe used to measure the stray flux round the
induction machine is very simple and cheap, as compared
∆>2s

∆>5s
[Hz]

[dB]

[dB]

∆>s
mh

mf

∆ s with other expensive ones presented in several papers

f

dealing with this diagnosis method, e.g. [12].

100 -36.71 -28.11 -8.60 1.45
150 -14.83 -12.29 -2.54 1.86
In industrial environment, the sensitivity of the flux coil
200 -49.71 -39.83 -9.88 1.40
could be affected by the existence of other possible magnetic
250 -24.37 -20.91 -3.45 1.89 fields, especially in case of motors supplied by power
300 -65.94 -55.92 -10.02 2.29 converters and installed near each other. In this case, it will
350 -30.99 -28.38 -2.61 2.01 be necessary to measure the magnetic field around each
400 -59.06 -49.95 -9.11 2.47 motor in different positions in order to define the place in
450 -54.64 -46.82 -7.82 1.81 which the flux measurement is less influenced by other
500 -68.96 -62.87 -6.09 1.57 nearby electrical drives.
550 -47.81 -48.19 0.37 1.91 The increase of the harmonics multiple of the fundamental
600 -66.37 -60.18 -6.19 1.45 in presence of bearing defects has not been yet theoretically
650 -50.48 -50.78 0.30 1.92 justified. However, generally, any asymmetry in an induction
700 -66.99 -67.31 0.32 2.06 motor could excite these harmonics. The problem consists in
750 -56.73 -57.38 0.64 1.77 distinguishing if this increase is due to a bearing fault, or to
800 -67.66 -66.66 -1.00 1.39 another kind of fault. Future theoretical and experimental
850 -65.47 -65.19 -0.28 2.54 works will be focused to solve this problem.
900 -66.71 -65.71 -0.99 1.75 All the results are encouraging future works concerning
950 -67.90 -66.53 -1.38 1.77 the use of other sensors (for measuring currents, stray fluxes
1000 -68.68 -65.96 -2.72 1.83 and accelerations) also for detecting other faults of the
induction machine.

474
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