energies

Article
Induction Motors Condition Monitoring System with
Fault Diagnosis Using a Hybrid Approach
Hong-Chan Chang *, Yu-Ming Jheng, Cheng-Chien Kuo and Yu-Min Hsueh
Department of Electrical Engineering, National Taiwan University of Science and Technology No.43,
Keelung Rd., Sec.4, Da’an Dist, Taipei 10607, Taiwan; 100m05001@stud.sju.edu.tw (Y.-M.J.);
cckuo@mail.ntust.edu.tw (C.-C.K.); D10307009@mail.ntust.edu.tw (Y.-M.H.)
* Correspondence: hcchang@mail.ntust.edu.tw; Tel.: +886-2737-6677




Received: 17 March 2019; Accepted: 9 April 2019; Published: 18 April 2019


Abstract: This study develops a condition monitoring system, which includes operating condition
monitoring (OCM) and fault diagnosis analysis (FDA). The OCM uses a vibration detection
approach based on the ISO 10816-1 and NEMA MG-1 international standards, and the FDA uses
a vibration-electrical hybrid approach based on various indices. The system can acquire real-time
vibration and electrical signals. Once an abnormal vibration has been detected by using OCM, the FDA
is applied to classify the type of faults. Laboratory results indicate that the OCM can successfully
diagnose induction motors healthy condition, and FDA can classify the various damages stator fault,
rotor fault, bearing fault and eccentric fault. The FDA with the hybrid approach is more reliable than
the traditional approach using electrical detection alone. The proposed condition monitoring system
can provide simple and clear maintenance information to improve the reliability of motor operations.

Keywords: operating condition monitoring; fault diagnosis analysis; hybrid approach

1. Introduction
Taking a large power plant in Taiwan as an example, each of its large thermal generator sets relies
on an auxiliary system with numerous high-voltage motors for operation. The elements of the auxiliary
system for the generator sets—which includes fans, coal pulverizers, gearboxes, fluid couplings,
and conveyor belts—are all driven by high-voltage motors, and these motors often require operation
under specialized conditions. Any breakdown in the auxiliary system not only affects the power
quality and reliability of the entire power system, but it can also result in enormous economic losses.
Thus, the importance of condition monitoring and fault diagnosis of induction motors in auxiliary
systems cannot be underestimated.
Various damage types were found, such as interturn short-circuit [1], broken rotor bar [2],
bearing inner ring failure, bearing outer ring failure, ball failure, cage failure [3], and eccentricity [4].
As for fault diagnosis of an induction motor, the literature has also indicated that approximately
30% of motor breakdowns are related to stators, 10% to rotors, 40% to bearings, and 20% to other
components [5].
A great deal of research proposes how to classify the damage types, such as stator breakdowns,
and have employed various approaches [6–12], including magnetic pendulous oscillation, motor current
signature analysis, instantaneous active and reactive power signature analyses, and total harmonic
voltage. Studies on rotor breakdowns [13–16] have used mathematical morphology and wavelet
analysis. Bearing breakdowns have been investigated using the root-multiple signal classification
method and neural networks [17,18]. As for breakdowns in other components, recent studies focused
on the relatively more common eccentricity problems, which were examined in References [19–22].

Energies 2019, 12, 1471; doi:10.3390/en12081471 www.mdpi.com/journal/energies

Energies 2019, 12, x FOR PEER REVIEW  2  of  12 

studies  focused  on  the  relatively  more  common  eccentricity  problems,  which  were  examined  in 
References [19–22]. 
Energies 2019, 12, 1471 2 of 12
Recently,  a  motor  diagnosis  manner  was  generally  used  in  industries,  which  is  called 
time‐based  maintenance  (TBM)  [23].  The  TBM  is  maintenance  performed  on  equipment  based  on 
calendar  schedules. 
Recently, a motorThis  means 
diagnosis that  the 
manner wasschedules 
generally will 
usedbe  important  which
in industries, for  routine  maintenance. 
is called time-based
However, the TBM may result in over maintenance to prevent considerable waste of manpower and 
maintenance (TBM) [23]. The TBM is maintenance performed on equipment based on calendar
resources.  This means that the schedules will be important for routine maintenance. However,
schedules.
In  industry 
the TBM may result 4.0,  thriving 
in over developments 
maintenance in  considerable
to prevent the  sensor,  waste
communication, 
of manpower and 
andinformation 
resources.
processing  industries 
In industry have developments
4.0, thriving gradually  made  the 
in the real‐time 
sensor, online  monitoring 
communication, of  motors 
and information a  real 
processing
possibility.  The  latest  trend  in  motor  maintenance  is  thus  condition‐based  maintenance 
industries have gradually made the real-time online monitoring of motors a real possibility. The latest (CBM), 
which inis motor
trend effective  in  accident 
maintenance prevention. 
is thus CBM  also 
condition-based allows  motors 
maintenance to which
(CBM), remain is reliable 
effectivethroughout 
in accident
their service time [23]. Thus, it is critically important to develop a condition monitoring system with 
prevention. CBM also allows motors to remain reliable throughout their service time [23]. Thus,
fault diagnosis using a vibration–electrical hybrid approach system for induction motors based on 
it is critically important to develop a condition monitoring system with fault diagnosis using a
CBM. 
vibration–electrical hybrid approach system for induction motors based on CBM.

2. Hardware Architecture 
2. Hardware Architecture

2.1. Overall Structure

2.1. Overall Structure 
Most condition monitoring systems (CMS) worldwide that are currently used for monitoring
Most condition monitoring systems (CMS) worldwide that are currently used for monitoring 
important
important motors
motors have
have a a 
hierarchical structure.
hierarchical  Figure
structure.  1 depicts
Figure  suchsuch 
1  depicts  a system, the front
a  system,  the end ofend 
front  which
of 
consists
which  of small, inexpensive,
consists  of  small,  reliable, fast, and
inexpensive,  simply constructed
reliable,  fast,  and  data acquisition/transmission
simply  constructed  data 
devices, embedded in crucial equipment on site, and the back end of which is a monitoring system.
acquisition/transmission devices, embedded in crucial equipment on site, and the back end of which 
Relay stations may
is  a  monitoring  be installed
system.  Relay between
stations  the
may front and backbetween 
be  installed  ends duethe 
to distance or back 
front  and  data transmission
ends  due  to 
considerations.
distance  or  data Relay stations must
transmission  have high Relay 
considerations.  expandability
stations and flexibility
must  to allow
have  high  effective and
expandability  and 
timely presentation of motor conditions to on-site operators at the front end and long-term recording
flexibility to allow effective and timely presentation of motor conditions to on‐site operators at the 
of operating
front  data
end  and  at the back
long‐term  end. Additionally,
recording  thedata 
of  operating  systemat  should be end. 
the  back  able to perform trend
Additionally,  the analyses
system 
based
should  onbe 
longitudinal data stored
able  to  perform  trend inanalyses 
its database.
based  The
on study developsdata 
longitudinal  condition
stored monitoring with fault
in  its  database.  The 
diagnosis embedded system in the front end.
study develops condition monitoring with fault diagnosis embedded system in the front end. 

 
Figure 1. Overall system diagram.
Energies 2019, 12, x FOR PEER REVIEW  3  of  12 

Energies 2019, 12, 1471 Figure 1. Overall system diagram.  3 of 12

In  Figure  2,  a  simple  embedded  system  is  proposed  for  condition  monitoring  and  fault 
In Figure 2, a simple embedded system is proposed for condition monitoring and fault diagnosis
diagnosis of induction motors. The front end embedded system prototype size is 240 × 170 × 30 mm. 
of induction
The  system motors.
assesses  The front
the  end embedded
current  condition system prototype
of  a  motor  through  240 × 170 ×
size is vibration  30 mm. The
detection.  system
When  an 
assesses the current
abnormality  condition
is  detected,  of a motor
electrical  throughis vibration
detection  used  in detection. When
conjunction  an abnormality
with  is detected,
vibration  detection  to 
electrical
determine  detection is usedtype 
the  possible  in conjunction withsystem 
of  fault.  This  vibration detection
adopts  to determine
a  triaxial  the possible
accelerometer  type of fault.
to  measure  the 
This system adopts a triaxial accelerometer to measure the vibration of the motor, non-contact capture
vibration of the motor, non‐contact capture of voltage, and current signals using Hall sensors. The 
of voltage,analog 
acquired  and current
signals  signals using Hall
are  passed  sensors.
through  The acquired
a  signal  analog
processing  signals
circuit  aretransmitted 
and  passed through a
to  an 
signal processing circuit and transmitted to an analog-to-digital converter, which converts
analog‐to‐digital  converter,  which  converts  them  into  digital  signals  and  passes  them  on  to  a  them into
digital signals and
microprocessor  for passes them on
processing.  to a microprocessor
Subsequently,  for processing.
fast‐screening  Subsequently,
fault  diagnosis  and  fast-screening
fast‐screening 
fault diagnosis and fast-screening condition monitoring are employed, and the results are displayed
condition monitoring are employed, and the results are displayed on the touchscreen in simple and 
on the touchscreen in simple and intuitive graphics. If intranet is available on site, the original signal
intuitive graphics. If intranet is available on site, the original signal data can be transmitted to the 
data can be transmitted to the server-side system, which will make the system operations even more
server‐side system, which will make the system operations even more comprehensive by conducting 
comprehensive
rigorous  analyses. by If 
conducting
intranet  is rigorous analyses.
not  available,  the  If intranet
original  is not
data  can available, the original
be  transported  using data can
a  secure 
be transported using a secure digital (SD) card to a computer for further analysis.
digital (SD) card to a computer for further analysis. As a means of data transportation, the SD card  As a means of
data
and  transportation,
intranet  are  not themutually 
SD card and intranetthe 
exclusive;  are not mutually
choice  exclusive;
between  the  two thedepends 
choice between
solely  the
on two
the 
depends solely on the availability
availability of on‐site intranet.  of on-site intranet.

Voltage Sensor Internet

3 Data Line
ADS8556
16 Data Line
Current Sensor
3 Data Line USB
ARM
LPC4088
LCD

3-Axis
ADS8556
Accelerometer
3 Data Line 16 Data Line SD Card

 
Figure 2. Front-end embedded system block diagram.
Figure 2. Front‐end embedded system block diagram. 

2.2. Sensor Modules

2.2. Sensor Modules 
The voltage and current sensors are used in this study were all Hall devices because of their high
The voltage and current sensors are used in this study were all Hall devices because of their 
safety and convenience. A triaxial accelerometer is used to measure accelerations along the three axes,
high  safety  and  convenience.  A  triaxial  accelerometer  is  used  to  measure  accelerations  along  the 
and its sensor is an integrated electronics piezoelectric (IEPE) circuit. Such sensors have sensitive
three axes, and its sensor is an integrated electronics piezoelectric (IEPE) circuit. Such sensors have 
built-in charge or voltage amplifiers because the current generated by the accelerometer is extremely
sensitive built‐in charge or voltage amplifiers because the current generated by the accelerometer is 
weak, and that signal interference can easily occur in the sensors without such amplifiers. The IEPE
extremely weak, and that signal interference can easily occur in the sensors without such amplifiers. 
transducer integrates these sensitive circuits and brings them close to the sensors to ensure greater
The IEPE transducer integrates these sensitive circuits and brings them close to the sensors to ensure 
noise immunity and easier packaging. The detailed sensor specifications are as listed in Table 1.
greater noise immunity and easier packaging. The detailed sensor specifications are as listed in Table 
1. 
Table 1. Specifications of sensors.

Sensors Model Table 1. Specifications of sensors. 

Type Measuring Range Frequency Bandwidth
Voltage Sensor
Sensors Model  CHVType 
50P/600 0~±800 V
Measuring Range  0~20 kHz
Frequency Bandwidth 
Current Sensor HTR 50-SB 0~±100 A 0~10 kHz
Voltage Sensor  CHV 50P/600  0~±800 V  0~20 kHz 
3-Axis Accelerometer AD100T ±50 g 0.3~12 kHz
Current Sensor 
ADC HTR 50‐SB 
ADS8556 0~±100 A 
16 Bits 0~10 kHz 
630 kSPS (Parallel)
3‐Axis Accelerometer  AD100T  ±50 g  0.3~12 kHz 
ADC  ADS8556  16 Bits  630 kSPS (Parallel) 
3. Software Process

3. Software Process 
3.1. Overall Structure
Figure 3 illustrates the process of the proposed hybrid approach. The CMS operations are divided
3.1. Overall Structure 
into two major parts: Operating condition monitoring (OCM) and fault diagnosis analysis (FDA).
When electrical and vibration signals have been acquired by the embedded system, the OCM module
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Figure  3  illustrates  the  process  of  the  proposed  hybrid  approach.  The  CMS  operations  are 
divided into two major parts: Operating condition monitoring (OCM) and fault diagnosis analysis 
Energies 2019, 12, 1471 4 of 12
(FDA). When electrical and vibration signals have been acquired by the embedded system, the OCM 
module  determines  the  current  condition  of  the  motor  using  vibration  indices  and  international 
standards. When an abnormality is detected in the motor’s operations, the system can classify the 
determines the current condition of the motor using vibration indices and international standards.
type  an
When of abnormality
detected  fault  through 
is detected vibration 
in the motor’s and  electrical 
operations, indices can
the system and  simultaneously 
classify informs 
the type of detected
maintenance personnel of the components requiring attention. The system can reduce maintenance 
fault through vibration and electrical indices and simultaneously informs maintenance personnel of
costs 
the or  advise requiring
components maintenance  personnel 
attention. of  the can
The system possible 
reducetype  of  fault,  thereby 
maintenance shortening 
costs or advise the  time 
maintenance
needed for troubleshooting. 
personnel of the possible type of fault, thereby shortening the time needed for troubleshooting.

Start

Measuring voltage,
current and vibration

Calculate the electrical

and vibration indicators
Operating Condition
Monitoring module
(OCM module)
Fault diagnosis
analysis module
Display the (FDA module)
operating status

No Displays the fault type

Index >ISO threshold-(1)?
Yes

Send message Maintenance work

No
Index >ISO threshold-(3)?
Yes
 
Figure 3. Overall hybrid approach flow chart.
Figure 3. Overall hybrid approach flow chart. 
3.2. OCM Module
3.2. OCM Module 
OCM relies on existing international standards as the basis for its judgments. The international
OCM relies on existing international standards as the basis for its judgments. The international 
standards used are primarily the ISO 10816-1 [24], which regards velocity control (Table 2), and the
standards used are primarily the ISO 10816‐1 [24], which regards velocity control (Table 2), and the 
NEMA MG-1 [25], which regards displacement control (Table 3).
NEMA MG‐1 [25], which regards displacement control (Table 3). 
Table 2. Thresholds by Std. ISO 10816-1.
Table 2. Thresholds by Std. ISO 10816‐1. 
Velocity (mm/s) Threshold Class I ≤ 15 kW
Velocity (mm/s) 
<1.12 Threshold  Class I ≤ 15 kW 
Good
<1.12 
1.12  
ISO threshold-(1) Good 
1.12~2.8
1.12  ISO threshold‐(1)  Satisfactory 
2.8 ISO threshold-(2)
1.12~2.8    Satisfactory 
2.8~7.1 Unsatisfactory
2.8 7.1 ISO threshold‐(2) 
ISO threshold-(3)  
2.8~7.1 
>7.1   Unsatisfactory 
Unacceptable
7.1  ISO threshold‐(3)   
>7.1  Table 3. Thresholds by  Std. NEMA MG-1.Unacceptable 

Thresholds
Table 3. Thresholds by Std. NEMA MG‐1. 
Synchronous Speed (rpm)
(Maximum Relative Shaft Displacement, Peak-peak)
1801–3600 0.0028 in (70 µm)
≤1800 0.0035 in (90 µm)
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Thresholds   
Synchronous Speed (rpm) 
(Maximum Relative Shaft Displacement, Peak‐peak) 
1801–3600  0.0028 in (70 μm) 
Energies 2019, 12, 1471 5 of 12
≤1800  0.0035 in (90 μm) 

Concerning  the
Concerning the  electrical
electrical  detection
detection  method,
method,  although
although  established
established  international
international  standards
standards  are
are 
available for the indices, comparable standards for the operations of motors are currently lacking. 
available for the indices, comparable standards for the operations of motors are currently lacking.
Hence,  if
Hence, if  the
the  information
information  currently
currently  atat  hand
hand  is
is  to
to  be
be  used
used  for
for  the
the assessment
assessment  of of  motor
motor  operating
operating 
conditions, algorithms must be employed to perform the necessary calculations. However, this is an 
conditions, algorithms must be employed to perform the necessary calculations. However, this is an
extremely time-consuming
extremely time‐consuming  undertaking 
undertaking for  microprocessors. 
for microprocessors. For thisFor  this  areason, 
reason, a  fast‐screening 
fast-screening condition
monitoring method is introduced instead. The method uses international standards on vibrations on 
condition  monitoring  method  is  introduced  instead.  The  method  uses  international  standards  to
vibrations to assess the condition of motors. According to the motor’s accelerations along the three 
assess the condition of motors. According to the motor’s accelerations along the three axes, first-order
axes,  first‐order 
integration integration 
is performed is  performed 
to obtain to  values
the velocity obtain to the 
bevelocity 
compared values 
with to 
ISO be  compared 
10816-1; with  ISO 
subsequently,
10816‐1; subsequently, second‐order integration is performed to obtain the displacement values to 
second-order integration is performed to obtain the displacement values to be compared with NEMA
be  compared 
MG-1. Figure with  NEMA the
4 describes MG‐1.  Figure  4  process
fast-screening describes  in the 
morefast‐screening 
detail. Because process  in  more divides
ISO 10816-1 detail. 
Because ISO 10816‐1 divides motor operations into four steps whereas NEMA MG‐1 only has two 
motor operations into four steps whereas NEMA MG-1 only has two steps, the method makes a logic
steps, the method makes a logic judgment on the velocity and displacement comparison results and 
judgment on the velocity and displacement comparison results and chooses the more serious ones
chooses the more serious ones for display in the system. The displayed results can be categorized 
for display in the system. The displayed results can be categorized into four levels: normal, caution,
into four levels: normal, caution, warning, and danger. 
warning, and danger.

Measurement of vibration
acceleration signal

Integral operation to obtain

speed, displacement

Compared to NEMA MG-1

international specification

The results are in The results are in

No Over Yes
accordance with ISO accordance with
NEMA MG-1
10816-1 international NEMA MG-1
threshold?
standard international standard

Compared to ISO
10816-1 international Danger
standard

Over ISO Yes Over ISO Yes Over ISO Yes

threshold-(1)? threshold-(2)? threshold-(3)?

No No No

Normal Caution Warning Danger

 
Figure 4. OCM module flow chart.
Figure 4. OCM module flow chart. 
3.3. FDA Module
3.3. FDA Module 
A two-stage hybrid approach for fault diagnosis analysis of induction motors is shown in
FigureA 5.
two‐stage 
The first hybrid 
stage ofapproach 
FDA usesfor  fault  diagnosis 
vibration detectionanalysis  of  induction 
for preliminary motors  of
classification is  the
shown  in 
faults.
Figure 5. The first stage of FDA uses vibration detection for preliminary classification of the faults. 
Numerous studies have been consulted to establish the indices for signal analysis, from which a small
Numerous 
number studies 
of key signalhave  been 
indices forconsulted 
vibrationto  establish  the 
acceleration are indices  for use
chosen for signal 
[26].analysis,  from  which  a 
small number of key signal indices for vibration acceleration are chosen for use [26]. 
The second stage of FDA involves using electrical detection to develop a more rigorous classification
systemThe 
ofsecond  stage 
fault types onof 
theFDA 
basisinvolves  using  electrical 
of the electrical indices. detection  to  develop 
The suitability a  more  index
of an electrical rigorous 
to
classification 
the detection of system 
a faultof  fault 
type cantypes  on  the  basis 
be determined of  the  electrical 
by observing the effectindices.  The  suitability 
of each electrical index onof the
an 
electrical  index fault
corresponding to  the  detection  of  a  fault  type  can  be  determined  by  observing  the  effect  of  each 
model.
electrical index on the corresponding fault model. 
1. Current unbalance rate (CUR): IEC 60034-1 [27] and IEEE Std. 141 [28] are used as a reference
for the definition of CUR, which is similar to voltage imbalance rate; that is, it is the ratio of the
three-phase current’s maximum deviation value to its mean value. When the motor is operating
Energies 2019, 12, 1471 6 of 12

at its rated output, it should avoid exceeding 10% of the recommended value, as indicated in the
following equations:
|I | + |Ib | + |Ic |
Iavg  = a
 
(1)
3
        
max |Ia | − Iavg , |Ib | − Iavg , |Ic | − Iavg 
CUR(%) =   × 100%, (2)
Iavg 

2. Current unbalance factor (CUF): IEC 60034-1 is used as a reference for CUF. Continuous operation
of over 5% should be avoided:
 0    
 I   1 1 1  Ia 
 I  = 1  1 a a2  Ib , a = 1∠120◦ ,
 1     
(3)
 
 2  3  
2
 
 
I 1 a a Ic


 
I 2 
CUF(%) =   × 100%. (4)
I 1 

3. Voltage total harmonic distortion (VTHD): IEEE Std. 519 [29] was used as a reference for VTHD,
which is expressed as a percentage and defined as the square root of the sum of harmonic voltages
divided by the fundamental frequency voltage, as shown in Equation (4). It is one of the means of
assessing the total harmonic voltage’s effect on the system.
qP
∞ 2
h = 2 Vh
THDV = × 100%. (5)
V1

4. Each voltage harmonic distortion (EVHD): IEEE Std. 519 is used as a reference for EVHD, which is
defined as the percentage of the fundamental frequency voltage that is individual harmonic
voltage, as shown in Equation (6). It is one of the means of assessing an individual harmonic
voltage’s effect on the system.
V
VHD(%) = h × 100%. (6)
V1

5. Current total harmonic distortion (CTHD): IEEE Std. 519 is used as a reference for CTHD, which is
expressed as a percentage and defined as the square root of the sum of harmonic currents divided
by the fundamental frequency voltage, as shown in Equation (7). CTHD is used to assess the total
harmonic current’s effect on the system.
qP
∞ 2
h = 2 Ih
THDI (%) = × 100%. (7)
I1

6. Each current harmonic distortion (ECHD): IEEE Std. 519 is used as a reference for ECHD.
Defined in the same vein as EVHD, ECHD refers to the rate of an individual harmonic current’s
voltage to the fundamental frequency voltage. Expressed in percentage, this index serves as a
means of assessing an individual harmonic current’s effect on the system.

Ih
IHD(%) = × 100%. (8)
I1

The suitability coefficient for an electrical index can be obtained by taking the mean of 50 data
points of an index in the fault model, and calculating its difference from that of a healthy motor,
Energies 2019, 12, 1471 7 of 12

followed by dividing the difference by the product of the difference (∆) between the maximum and
minimum values in the 50 data points of the same index in the fault model and that of a healthy
Energies 2019, 12, x FOR PEER REVIEW  motor.
7  of  12 
Fault diagnosis in induction motors can be divided into two stages. The first is a preliminary
minimum 
classification ofvalues in 
fault type the 50  data vibration
through points of detection,
the  same index 
and the in  the fault 
second ismodel  and  that 
a further of a healthy 
classification of fault
motor. 
type through electrical detection. The following is a description of the fast-screening fault diagnosis of
Fault diagnosis in induction motors can be divided into two stages. The first is a preliminary 
the two stages.
classification of fault type through vibration detection, and the second is a further classification of 
In thetype 
fault  firstthrough 
stage, the motor’s
electrical  acceleration
detection.  signals along
The  following  the three axes
is  a  description  arefast‐screening 
of  the  acquired to fault 
calculate
the statistical indices and peak values and to determine the corresponding thresholds. As the values
diagnosis of the two stages. 
for motors with stator and rotor faults are statistically closer to those for healthy motors, they are
In the first stage, the motor’s acceleration signals along the three axes are acquired to calculate 
considered as belonging to the same fault group (Group 1). Bearing and misalignment faults are
the statistical indices and peak values and to determine the corresponding thresholds. As the values 
for motors with stator and rotor faults are statistically closer to those for healthy motors, they are 
considered to belong to the same fault group (Group 2) because the index values for such motors are
considered 
significantly as  belonging 
higher than thoseto  the 
for same  fault 
healthy group  (Group 
motors. In summary,1).  Bearing 
peakand  misalignment 
values can be used faults  are 
to roughly
considered to belong to the same fault group (Group 2) because the index values for such motors 
divide fault types into two groups.
are  significantly  higher  than  those  for  healthy  motors.  In  summary,  peak  values  can  be  used  to 
The second stage is to acquire the motor’s signals for the three-phase voltages and currents
roughly divide fault types into two groups. 
for determination of the electrical indices. According to the aforementioned suitability assessment,
The second stage is to acquire the motor’s signals for the three‐phase voltages and currents for 
current unbalance of 
determination  rate
the (CUR), current
electrical  unbalance
indices.  According factor
to  the (CUF), voltage total
aforementioned  harmonic
suitability  distortion
assessment, 
(VTHD), each voltage harmonic distortion (EVHD), current total harmonic distortion
current  unbalance  rate  (CUR),  current  unbalance  factor  (CUF),  voltage  total  harmonic  distortion  (CTHD), and each
current(VTHD), each voltage harmonic distortion (EVHD), current total harmonic distortion (CTHD), and  or
harmonic distortion (ECHD) are classified as either current imbalance electrical indices
each current harmonic distortion (ECHD) are classified as either current imbalance electrical indices 
harmonic distortion electrical indices for fast-screening fault diagnosis. If the result of the first stage is
Group or 1,
harmonic 
then thedistortion 
screening electrical 
rules for indices  for  fast‐screening 
the second stage are as fault  diagnosis. 
follows: If theIf electrical
the  result indices
of  the  first 
in both
stage is Group 1, then the screening rules for the second stage are as follows: If the electrical indices 
current imbalance and harmonic distortion are all lower than the international standard threshold,
in  both  current  imbalance  and  harmonic  distortion  are  all  lower  than  the  international  standard 
the motor is identified as healthy; if any electrical index in current imbalance exceeds the international
threshold, the motor is identified as healthy; if any electrical index in current imbalance exceeds the 
standard threshold, it is identified as a stator fault; and if any electrical index in harmonic distortion
international  standard  threshold,  it  is  identified  as  a  stator  fault;  and  if  any  electrical  index  in 
exceeds the international standard threshold, it is identified as a rotor fault. As the fast-screening
harmonic distortion exceeds the international standard threshold, it is identified as a rotor fault. As 
fault the fast‐screening fault diagnosis is only based on a logic judgment of whether a value exceeds the 
diagnosis is only based on a logic judgment of whether a value exceeds the threshold or not,
it is unable
threshold to distinguish
or  not,  it  is whether
unable  to a distinguish 
fault occurswhether 
in the stator
a  fault oroccurs 
rotor in 
when electrical
the  stator  indices
or  rotor  when in both
current imbalance and harmonic distortion exceed the threshold.
electrical indices in both current imbalance and harmonic distortion exceed the threshold. 

Three - axis vibration

acceleration signal

Select the acceleration

fitness index (Peak)

Set the accelerometer

threshold
Electrical indicators
threshold
CIR：10 % No Over the Yes
CIF：2.5 % threshold?
VTHD：5 %
EVHD：3 % (Group 1)
(Group 2)
CTHD：5 % Health
Bearing
ECHD：4 % Stator
Eccentric
Rotor

No No Can not distinguish

Health
stator or rotor
Two types of indicators Two types of indicators
are above threshold are above threshold
Can not distinguish Can not distinguish
stator or rotor Yes One of them is Yes stator or rotor
greater than the
Current threshold Current
imbalance imbalance
What kind of indicators What kind of indicators
Stator Fault Misalignment Fault
over the threshold? over the threshold?
Harmonic Harmonic
distortion distortion
Rotor Fault Bearing Fault
 
Figure 5. FDA module two-stage hybrid approach flow chart.
Energies 2019, 12, 1471 8 of 12

4. Experimental Results and Analysis

4.1. OCM Results and Analysis

The rules are established based on two sets of international standards: ISO 10816-1 and NEMA
MG-1. When the displacement is judged to be “Normal” according to NEMA MG-1, the velocity
would be used to assess the level of operating condition as per IOS 10816-1; conversely, when the
displacement is judged to be “Danger” as per NEMA MG-1, the operating condition would be rated as
“Danger”. The comprehensive results are shown in (Table 4).

Table 4. Operating condition monitoring rules.

ISO 10816-1
Good Acceptable Unsatisfactory Unacceptable
NEMA MG-1
Normal Normal Caution Warning Danger
Danger Danger Danger Danger Danger

The feasibility assessment of the motor condition monitoring system requires longitudinal data.
However, such data are lacking because the proposed system had not yet begun on-site testing. Hence,
the feasibility of the proposed system is assessed using a vibration exciter in the laboratory to generate
varying vibrations, the velocities, and displacements of which, after integral operations, is fast-screened
to determine the operating conditions.

4.2. FDA Results and Analysis

To obtain standard sample data for the proposed fault diagnosis, this study used induction motors
with identical specifications (220 V, 7 A, 60 Hz, 2 HP, and four poles) to create four common fault
models, and then used a healthy model for contrast. The experimental scale-down fault models are
described as follows:

1. Stator fault: This fault occurs when the insulation layer of the stator coils is damaged by friction,
aging, overheating, humidity, or corona. In the present study, a mild inter-coil short circuit is
simulated by two coils short circuit after part of their insulation layer had been lightly scraped off
(Figure 6a).
2. Rotor fault: If a motor is overloaded or restarted often, stress or heat buildup can cause the
breakage of a rotor bar. This study consulted the literature and drilled a hole 7 mm in diameter
and 30 mm in depth into the rotor bar (Figure 6b).
3. Bearing fault: The bearing outer ring is prone to damage when the motor is overloaded, overheated,
or intruded by foreign objects. In this study, electric heating is applied to melt a hole in the
bearing outer ring under the premise that the bearing and other components were not to be
affected. The hole was 1 mm in diameter and depth (Figure 6c).
4. Misalignment fault: When the motor is with load, the coupling can cause misalignment at both
ends due to human, environmental, or operational reasons, which in turn induces problems such
as noise and heating. Because of safety considerations, the present study uses a healthy motor
but displaced the coupling and load 0.5 mm upward (Figure 6d).
Energies 2019, 12, 1471 9 of 12
Energies 2019, 12, x FOR PEER REVIEW  9  of  12 

 
Figure
Figure  6. Fourexperimental 
6.  Four  experimentalmodels: 
models:(a) (a) Stator
Stator  fault,
fault,  (b)  (b) rotor
rotor  fault,
fault,  (c) bearing
(c)  bearing  fault,
fault,  (d) 
(d) misalignment fault.
misalignment fault. 

To
To verify
verify the
the effectiveness
effectiveness of
of the
the proposed
proposed system,
system, the
the aforementioned
aforementioned stator
stator interturn
interturn short
short 
circuit, rotor bar breaking, bearing outer ring damage, and misalignment fault models
circuit, rotor bar breaking, bearing outer ring damage, and misalignment fault models and a healthy  and a healthy
motor were employed for measurement. The sampling rate was 10 kHz, and 50 data entries were taken
motor were employed for measurement. The sampling rate was 10 kHz, and 50 data entries were 
for each
taken  motor,
for  each  amounting to 250 data
motor,  amounting  points
to  250  inpoints 
data  total. The data were
in  total.  usedwere 
The  data  to compare the
used  to  diagnostic
compare  the 
results when electrical detection alone was employed and the proposed hybrid approach
diagnostic results when electrical detection alone was employed and the proposed hybrid approach  of combining
vibration detection and electrical detection was used. From the results of Table 5, it is shown that the
of combining vibration detection and electrical detection was used. From the results of Table 5, it is 
five experimental models can be effectively distinguished using the hybrid approach.
shown that the five experimental models can be effectively distinguished using the hybrid approach. 
Table 5. FDA results classification accuracy (%).
Table 5. FDA results classification accuracy (%). 
Diagnosis
  Fault Type  H S R B M
Fault Type H  S  R  B  M 
Diagnosis   
H 100 0 0 0 0
H  100  0  0  0  4 *10 
S 0 100 0 0
0 *2
4 *1 
RS  0 0  0100  100 0  0 0  00 *2 
B 0 0 0 100 0
R  0  0  100  0  0 
96 *1
M
B  0 0  0 0  0 0  0 100  0 
100 *2
H: Health, S: Stator, R: Rotor,
96 *1 
*1 : Electrical approach; *2 : Hybrid approach.
M  B: Bearing, M: Misalignment;
0  0  0  0 
100 *2 
H: Health, S: Stator, R: Rotor, B: Bearing, M: Misalignment; *1: Electrical approach; *2: Hybrid approach. 
Table 6 presents the testing results of the samples, suggesting that electrical detection alone and
Table 6 presents the testing results of the samples, suggesting that electrical detection alone and 
the proposed hybrid approach are both able to accurately identify the healthy motor and the stator,
the proposed hybrid approach are both able to accurately identify the healthy motor and the stator, 
rotor, and bearing faults; however, for misalignment faults, electrical detection identified 20.76%
rotor, and bearing faults; however, for misalignment faults, electrical detection identified 20.76% as 
as misalignment faults and misidentified 37.85% as stator faults. By contrast, the proposed hybrid
misalignment 
approach faults 
was able to and  misidentified 
accurately identify 37.85%  as  stator 
misalignment faults. 
faults. For By  contrast, 
each the model,
individual proposed  hybrid 
the hybrid
approach was able to accurately identify misalignment faults. For each individual model, the hybrid 
approach was superior to electrical detection in fault diagnosis. For example, the hybrid approach was
approach was superior to electrical detection in fault diagnosis. For example, the hybrid approach 
able to identify 56.21% of stator faults whereas electrical detection was only able to identify 37.85%.
was  able  to  identify  56.21%  of  stator  faults  whereas  electrical  detection  was  only  able  to  identify 
37.85%. 
 
Energies 2019, 12, 1471 10 of 12

Table 6. FDA results classification accuracy (%).

Diagnosis
H S R B M
Fault Type
99.99 *1 0.01 *1 0.61 *1 0.01 *1 0.01 *1
H
99.91 *2 0.01 *2 0.01 *2 0 *2 0 *2
0 *1 37.85 *1 16.05 *1 19.61 *1 37.85 *1
S
0.01 *2 56.21 *2 38.99 *2 0.01 *2 0.01 *2
0 *1 19.83 *1 51.4 *1 27.13 *1 20.45 *1
R
0.01 *2 43.77 *2 60.99 *2 0.01 *2 0 *2
0 *1 21.54 *1 24.02 *1 41.3 *1 20.93 *1
B
0.04 *2 0 *2 0 *2 99.97 *2 0.01 *2
0 *1 20.76 *1 7.92 *1 11.94 *1 20.76 *1
M
0 *2 0 *2 0 *2 0.01 *2 99.98 *2
H: Health, S: Stator, R: Rotor, B: Bearing, M: Misalignment; *1 : Electrical approach; *2 : Hybrid approach.

5. Conclusions
The present study successfully develops a condition-based system which can monitor various
types of motor faults by using the proposed vibration-electrical hybrid approach. The system uses
vibration detection for operating condition monitoring in accordance with rules drawn from the ISO
10816-1 and NEMA MG-1 standards. Laboratory test results indicate that the system can correctly
monitor the operating conditions of a motor as per the rules. For fault diagnosis analysis, the system
uses vibration detection and electrical detection for fault classification. The results of laboratory
tests show that the classification accuracy of the proposed hybrid system is superior to that of the
electrical approach to fault type identification. Additionally, the system is able to issue simple and
clear instructions, which is a substantial improvement on existing systems and highly convenient for
on-site personnel.

Author Contributions: Conceptualization, H.-C.C. and C.-C.K.; methodology, H.-C.C. and C.-C.K.; software,
Y.-M.J. and Y.-M.H.; validation, Y.-M.J. and Y.-M.H.; data curation, H.-C.C.; writing—original draft preparation,
Y.-M.J.
Funding: MOST-105-2221-E-011-081-MY3.
Acknowledgments: This paper supports the research funding of the Ministry of Science and Technology,
Taiwan under Grant MOST-105-2221-E-011-081-MY3 is gratefully acknowledged.
Conflicts of Interest: The authors declare no conflict of interest.

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