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Causes and failures classification of industrial electric motor

Conference Paper · October 2016

DOI: 10.1109/ANDESCON.2016.7836190

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 Causes and Failures Classification
of Industrial Electric Motor
Alvaro Jose Bazurto Enrique Ciro Quispe
Assistant Research Full Professor
Universidad Autónoma de Occidente Universidad Autónoma de Occidente
Cali, Colombia Cali, Colombia
alvaro.bazurto@correounivalle.edu.co ecquispe@uao.edu.co
Abstract— The energy management of electric motors is an
important part of the industrial energy management, because the
electric motors consume about 70% of industrial electricity. The
energy management allows reduce electricity consumption
through the increase efficiency of industrial processes and reduce
CO2 emissions. Knowing the cause of failure in electric motors is
a very important element of the industrial energy management.
This paper presents a review of the causes and classification
of the most common failures in industrial electric motors. The
work is complemented by a classification of faults made from
surveys and information provided by repair centers electrical
machines in southwestern Colombian
Keywords—Fault, Failures, Electric Motor, Induction Motor,
Classification, Winding, Core, Coil.
I. INTRODUCTION
After the oil crisis of the 70's and global awareness about
climate change, it began consolidating in different countries the
concept of sustainable development, which is based among
other things, the energy efficient use as well as energy
management. In some countries such as the case of Colombia,
the government has implemented programs for promotion,
education, regulation, marketing and the use of high-efficiency
equipment as part of national strategies in order to increase the
energy efficiency and reduce the CO2 emissions.
Approximately 68% of the electricity consumed worldwide in
the industrial sector and 46% of global electricity consumption
are used to electric motor drive systems. Therefore, efficiency
and reliability of electric motors operation are important goals
to improve the industry energy efficiency and to reduce both
the energy consumption as well as the production costs [1].
Increasing energy efficiency means lower energy
consumption while maintaining the same production capacity
and this is achieved by two-way, high-efficiency equipment
applied and implementing an energy management system.
Unknown the new technologies of energy efficient motors,
the selection errors and improper use of equipment, might
leads to take wrong decisions by consumers, industry, the
energy sector and the institutions of government. Situation that
ultimately has a negative impact on efficiency of industrial
systems and generate economic losses for all sectors of the
productive chain.
1
Rosaura Castrillon Mendoza
Assistant Professor
Universidad Autónoma de Occidente
Cali, Colombia
rcastrillon@uao.edu.co
An important element to consider in the energy efficient
management is the causes and classification of failures in
electric motors, because its impact on the reliability of
operation. Also should be considered that not all machine
failures occur randomly and instantly. These can be generated
by progressive and degenerative form and have a negatively
impact on the operation torque, the working temperature,
losses, mechanical vibration among other elements that finally
reduce the efficiency of the production system.
By other hand must also consider the number of repairs
influences the efficiency of the electric motor, since the motor
losses tend to increase with each repair, studies show that each
repair can reduce efficiency by up to 2% [2].
This paper presents a review of the causes and
classification of the most common failures in industrial electric
motors. The work is complemented by a classification of faults
made from surveys and information provided by repair centers
electrical machines in southwestern Colombian.
II. CLASSIFICATION FAULT – REVIEW
The study of failures in electric motors is a subject of
interest to the academic and industrial community, the trend
research focuses on methods to measure and identify faults by
on-line or off-line tests. Within these researcher some authors
have made classifications and categories of motor failures by
the nature of the failure (electrical, mechanical), fault location
(stator, rotor) among others. Within these investigations some
authors have made classifications and defined categories of
motor failures, by the nature of the failure (electrical,
mechanical), fault location (stator, rotor) among others.
A. Source of the failures
The classification of the origin of the faults in an electric
motor can be represented in two levels, the internal source and
the external source.
At this point, it is important to specify the definition of
failure in an electrical machine, for example in [3] it is defined
how change in any component of the machine that prevents
proper operation. It is also possible to define it as the
unavailability of an element to perform an intended action. In
this sense the stages of failure are: insipiencia of failure,
material fatigue, deterioration thereof and the fault itself.
 In [3] the causes of failures are classified as: Failures from internal sources are caused by
manufacturing errors and the deterioration of materials
• Inherent weakness of material, design and manufacturing.
constituting the machine, while failures from external sources
• Misuse or application of efforts in the wrong direction. occur as a result of interactions with the environment, the
• The gradual deterioration as a result of wear, tear, fatigue power supply and the load.
by stress or corrosion.
Fault source
Jayaswal et al. [3], conclude that early identification of external
failures ensures security, reliability and easy maintenance of motor
the machines.
Several studies as [4]–[8], [10]are agree in classify, the
rotor and stator failures as a combination of several forces Mechancial Electric Environmental

acting on each of these components. In the TABLE I. a

classification of these factors is presented.
Load Transitory and
TABLE I. SOURCE FAULT CLASSIFICATION voltage Moisture
Stress thermal (Aging, overload, work
variation
fluctuations
cycles)
Stress electric (Insulation, corona effect,
transient)
Stator Connection and
Stress mechanical (Coil displacement,
Overload installation Temperature
mechanical rubs)
wrong
Stress environmental (Pollution,
moisture, abrasion, foreign objects.)
Stress thermal
Stress electromagnetic Assembly Voltage
Stress residual Pollution
Rotor wrong imbalance
Stress dynamic
Stress mechanical
Stress Environmental
Fig. 2. Fault source external motor classification

B. Failures classification
A complete classification of failures in electric motors is
presented in [9], Bhowmik et al. propose two groups of faults,
which are classified by their source. The Fig. 1 and Fig. 2 show
the proposal made by these authors:
Several research about motor failures [5], [6], [9] – [11] , agree
as a result of the experience of manufacturers, repair centers
and academic studies, that aproximately the faults distribution
percentage in electric motors is: 45 % in the bearings, 35% in
the stator, 10 % in the rotor and the remaining 10 % in other
categories (View Fig. 3).

Fault Source
Inside Motor Others
Fault type

Rotor

Mechanical Electric Stator

Bearings

Sheets and coils 0 20 40

displacement Insulation Fault
Ocurrence percentege [%]

Break of rotor Fig. 3. Riview literature distribution fault

Bearings Fault bars
Another classification of faults is presented [5], in this paper
the authors present categories of fault location, then an
Dynamic and Magnetic individual analysis is presented for each type of failure:
static eccentricity circuit fault
 Failure bearings: Generally, a bearing is an
Fig. 1. Source internal fault classification [9] arrangement of two concentric rings, where a rolling

2
 element as balls or cylinders are housed inside. The
bearing failures can be localized (chips, cracks,
subsidence) or distributed (misalignments,
undulations, roughness).

 Failure stator: Most failures stator have as a source

thermal stress, electrical stress or critical
environmental conditions. The most frequent faults in
the stator are short coil to coil, fault between phases,
coil open circuit or ground phase. The authors in [9]
classify faults in the stator as follows:

1. Frame: Vibration problems, circulating currents, Fig. 4. Results failures distribution

ground faults and cooling problems occur.
In Fig. 5 and Fig. 6 both electrical and mechanical failures
2. Core laminations: Core loss of rigidity and hot observed in CA motors.
spots.
3. Stator windings: They can occur in the heads of
coils or slots, some of the causes of failures in the
winding are weakening the insulation between
turns or points localized damage to the lead,
displacement of drivers, moisture contamination,
oil or another element.

 Fault rotor: The rotor failures can occur by electrical

problems in manufacturing defects, breakage of bars.
The defects associated with the bars has its origin
mainly on thermal stress or fatigue product operating
transients such as start-ups, this problem is usually
Fig. 5. Electric Failures distribution stator CA
associated with high power motors. The second case
is frequent mechanical problems such as
misalignment of the motor or load variation

 Failures eccentricity: The eccentricity in electrical

machines is associated with a variation in the air gap.
Some causes of this phenomenon can be: bent shafts,
wear on the bearings, mechanical vibrations or
resonances.

III. SURVEY FAULT CLASIFICATION INDUSTRIAL

A survey of the main centers of repair of electrical
machines of Valle del Cauca, Colombia, in order to observe the
distribution of failures in electric motors CA and CD is Fig. 6. Mechanical Failures distribution rotor CA
performed. The survey sample is taken from the database
repair centers in the period from January – June year 2016, In Fig. 7 and Fig. 8 both as mechanical electrical faults
approximately 500 electric motors were analyzed in this period observed in DC motors.
with power between from 1 to 300 HP. In Fig. 4 It shows that
mechanical failures are predominant source of power failures.

3

Fig. 7. Electric Failures distribution stator CD
Fig. 8. Mechanical Failures distribution rotor CD
IV. CONCLUSIONS
Squirrel cage induction motors are electric motors most
widely used in industry because of its low cost and control
technologies that have allowed its use in most industrial
applications.
The mechanical component is the most significant part of
the electrical motor and which is exposed to increased wear; as
such a mechanical failures are the most common in electric
motors. This is evidenced in the survey, where approximately
70% of failures are of mechanical origin, therefore it is
important to verify the correct selection and proper installation
of the motor.
Motor failures of electrical origin are associated mainly
with the motor operating temperature and aging of the
insulation, which triggers fault of interturn short-circuit, short-
circuit between phases or coils to ground. Therefore, selecting
the right motor for loading and take into account the ambient
temperature of the motor operation, are important elements to
prevent early engine failure.
In the maintenance it is important to check the power
quality of the network in order to detect voltage fluctuations,
voltage harmonics, overvoltage or voltage unbalance. Another
important aspect to consider is the selection, installation and
bearing lubrication since they are a major source of failure.
It is important to use efficient methods for repairing
motors, to ensure that motor efficiency is not affected
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significantly, because it is known that improper repair can
significantly reduce efficiency.
Avoid and reduce failures of electric motors allows a more
efficient production system, because unwanted stops that
generate large losses for companies is reduced.
ACKNOWLEDGMENT
The authors wish to acknowledge to Colciencias for
financing the project "Energy Management in Industrial
Electric Motors Systems - Geme". Project developed within the
framework of the Colombian Knowledge Network in Energy
Efficiency RECIEE, from which this article is a partial product.
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