1

New Methodology to Faults Detection in

Induction Motors via MCSA
M. J. Castelli, Member, IEEE, J.P. Fossati, Member, IEEE and M. T. Andrade, Senior Member, IEEE

coils short-circuits.
Abstract— This paper introduces a new methodology for Mechanical faults are commonly associated to rotor or rotor
analysis of faults in induction motors based on MCSA using the related damage. The most important mechanical failures are:
Fast Fourier Transform (FFT). The report describes the rotor broken bars and rings, bearings damage, irregular gaps
methodology used for determining the exact amplitude of the
(static and dynamics eccentricities), unbalances, refrigeration
harmonic fault, regardless of the sampling time used, thus making
data acquisition and subsequent analysis easier. Another troubles, etc.
advantage of this method is that it only needs for its In general, faults in electrical machines are dominated by
implementation the measurement of the stator current. failures in bearings and stator coils. Focused on asynchronous
motors with squirrel cage rotor statistics are the following [2],
Index Terms— Fault Detection; Induction Motor [6]:
Maintenance; MCSA,
• Bearings fault related: 41%
• Stator faults related: 37%
I. INTRODUCTION
• Rotor faults related: 10:
I N industrialized countries, induction motors are responsible
for the 40% to 50% of energy consumption [1]. Recent
studies indicate that 90% of the failures in machines occur
• Other problems: 12%
Failures Statistics
due to miss function of the internal components, such as the
main motor [1].
Many methods have been proposed for induction motors 12%
failure detection, from sensorless methods to injection of high 10%
Bearings
frequency current into the stator coil [1], [3] - [5]. 41% Stator
Rotor
A large number of techniques for monitoring and diagnosis
Others
of asynchronous motors are based on the analysis of the
frequency spectrum, resulting from the FFT, however the data
37%
acquisition time required is excessively high to implementate
in a industrial environment [6].
First of all, a brief description of the most important faults
in induction motor is presented in conjunction with a first Fig. 1. Failures statistics in induction motors.
classification of these failures. Then, the mathematical data
acquisition model is introduced. After that, monitoring and III. DATA ACQUISITION MODEL
diagnosis methodology is described. Finally, laboratory and
industrial tests are analyzed in order to validate the Considering a sufficiently high number of samples (eight
methodology. seconds of sampling time at 5 kHz of sampling frequency), we
have that the ratio a k of discrete Fourier series converges to
II. FAILURES IN INDUCTION MOTORS
the a k of continuing Fourier series.
Most failures in induction motors can be classified in two
main groups: isolation failures and mechanical failures [7]. In Taking a signal f (t ) = β sin(ϖt + θ ) , and x = ωt ,
[7], failures in asynchronous motors are briefly presented. then f ( x ) = β sin( x + θ ) . If k + y periods are sampled,
Isolation failures are commonly characterised by stator with k an integer, and y real, we have the following expression
for the k-th harmonic (taking into account a sufficiently large
number of samples):
This work was supported in part by the PDT of the Uruguayan Ministry of
Education and ALFEX S.A.
M. J. Castelli is with the CITEM of the University of Montevideo, 2πk + 2πy 2πk
1 − xj

∫ β sin( x + θ )e
Montevideo, C.P. 11300, Uruguay (e-mail: mcastelli@um.edu.uy). 2πk + 2πy
J. P. Fossati is with the CITEM of the University of Montevideo,
ak = dx (1)
Montevideo, C.P. 11300, Uruguay (e-mail: jfossati@um.edu.uy).
2πk + 2πy 0
M. T. Andrade is with ALFEX S.A. Montevideo, C.P. 11100, Uruguay (e-
mail: mandrade@ieee.org).
978-1-4244-2218-0/08/$25.00 ©2008 IEEE.
 2

Solving (1): T = 2πk + 2Ω

Real part of a k : Based on the last expression, we could see that when we
consider a entire number of cycles ( Ω = 0 or y = 0) we have
 cos( 2 π y + θ + 4 k π ) cos( 2 π y + θ )  that β = 2 ak
− 4π ( y + 2 k )
−
4π y 
  (2) Being k the main harmonic, we can appreciate what
β
 cos( θ ) k cos( θ )( 2 y + k ) 
happens with this and the others when y ≠ 0
 − 4 π ( y + k )( y + 2 k ) + 4 π y ( y + k ) 
  The function
2 ak
Imaginary part of a k : f ( y) = (7)
β
 sin( 2 π y + θ + 4 π k ) sin( 2 π y + θ )  Lets see what happens with the main harmonic and the
 − 
4π ( y + 2 k ) 4π y (3) followings when y ≠ 0 .
β  
 sin( θ ) k sin( θ ) k  As follows an alternative in order to asses the true
 + 4π ( y + k ) + 4π y ( y + k )  magnitude of the signal introduced by the failure is described
 
Taking into account that the k-th is the main harmonic:
If 0 < y < 0.5 the second main harmonic is the (k+1)-th.
And
If0 > y > −0.5 the second main harmonic is the (k-1)-th
β 2( y (( y + 2k ) cos(2πy + θ ) Calling Ψ to the relationship between the main harmonic
ak = − 2 cos(θ )( y + k )) cos(2πy + θ + 4kπ ) and the second main harmonic:
4π 
− y (( y + 2k ) sin(2πy + θ )
ak
Ψ= (8)
− 2 sin(θ )k ) sin(2πy + θ + 4πk ) (4) a k ±1
− 2 cos(θ )( y 2 + 3ky + 2k 2 ) cos(2πy + θ )
1 sin(π y )
− 2 sin(θ )k ( y + 2k ) sin(2πy + θ ) +  2 2π y (1 − y )
 1 Ψ= = (9)
(2(cos(θ )) + 1) y 2  y ( y + 2k ) sin(π ( y − 1)) y
+ 2(2(cos(θ ))2 + 1)ky + 4k 2 ) 
 2π ( y − 1)

Taking the limit of a k when k tends to infinite: Since this, an expression for y (Ψ ) could be found:

β 1 1 1
limak = [− 2(cos(θ ) cos(2π +θ ) + sin(θ ) sin(2πy +θ ) −1)]2 y =
4π y Ψ +1 (10)
k →∞ .
(k ∈ Ν) In the other hand, for an N and T sufficiently large:

sin(πy) sin(πy )
=β (5) 2 ak = β (11)
2πy πy
If πy = Ω then: From the last two equations, we can deduce:

sin(Ω) a k 2π
lim 2 a k = β =β
Ω  π 
k →∞ (6) sin  (Ψ + 1)
ψ + 1  (12)
(k ∈ Ν )

With
 3

This gives the exact amplitude of the fault signal. It this  1− s  
also possible to deduce the exact frequency the defect, f ec = f s .(r ± nd ).  ± nws  (16)
provided by:   p  
f ec = eccentricity frequency
1
k± f s = supply frequency
f = Ψ +1 r = number of slots
tm (13) nd = + −
1
Therefore, from (12) and (13), it is possible to deduce both,
p = pole pairs
the extent of the defect and its exact frequency of occurrence. s = slip frequency
Fig 2. shows the relationship between main and secondary n ws = 1, 3, 5…
harmonics taking into account a sufficiently large number of
samples. Bearing failures [9][10]:
f 0 = 0.4 ∗ n ∗ f rm
(17)
f1 = 0.6 ∗ n ∗ f rm
f 0 = lower frequency
f 1 = upper frequency
n = balls number
f rm = rotor mechanical frequency

First, it is necessary to know the motor’s simplified

equivalent circuit to study. Based on the simplified equivalent
circuit, and doing current and voltage measurement, it is
possible to find the slip motor. It should be borne in mind that
Fig. 2. Relationship between main and secondary harmonics taking into the slip found in this way is very sensitive to small variations
account a sufficiently large number of samples.
of the parameters calculated before. Therefore the realization
of an FFT of the current signal is necessary, as the harmonics
IV. MONITORING AND DIAGNOSIS METHODOLOGY
of eccentricity of the motor are always present in this spectrum
Known the fault frequency equations for each main defect and this harmonics give us, from the applications of (12) and
(broken bars, short-circuits, eccentricity and bearings failure) (13), an accurate measure of the fault frequency, which form
(extensible detailed in bibliography): (18) [10] provides a very precise measurement of slip
frequency, which is used to identify all the failure frequencies.
Broken bars [1][8] :
f b = f1 (1 ± 2.s ) (14) f ec = f s ± k ⋅ f rm (18)
f b = broken bars frequency
Where
f 1 = supply frequency
s = slip frequency f ec = eccentricity frequency
Short-circuits [6] : f s = supply frequency
n  k = 1, 2, 3…
f st = f s . .(1 − s ) ± k  (15)
p  f rm = rotor mechanical frequency
f st = short-circuit frequency
From the current sampling and the slip frequency of the
f s = supply frequency motor, it is possible to determine the frequencies for each
n = 1, 2, 3… failure study.
p = pole pairs It is necessary to remark the fact that in the data acquisition,
the FFT of the measured current was normalized as a function
s = slip frequency
of the primary harmonic amplitude, in order to obtain fault
k = 1, 3, 5… amplitude independent form the motor load condition.
After determining the true amplitudes and frequencies of
Eccentricities [2]: defect, it is necessary to study its evolution in time, for the
selected motors.
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V. LABORATORY TESTS RESULTS

In this section, laboratory tests results are presented for
broken rotor bars and short-circuit defects:

Fig. 5. FFT with 3 broken bars.

Fig. 3. View of the work bench.
TABLE I
Broken bars study: RESULTS OF BROKEN BARS
Frec Amp Nr Broken
s = 0.0473 (1429rpm) (Hz) (%) Bars

f b − = 45.25 Hz 45.25 0,2937 0

45.25 1,028 1
f b + = 54.75 Hz 45.25 1,83 2
45.25 1,962 3

2,5

2
Amplitude (%)

1,5

0,5

0
0 0,5 1 1,5 2 2,5 3 3,5
Nr of Broken Bars

Fig. 6. Broken bars fault evolution.

Short-circuits study:

Fig. 4. FFT of the initial condition for broken bars. s = 0.0153 (1477 rpm)

f sc = 25.37 Hz
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VI. INDUSTRIAL TESTS RESULTS

In this section, the results of an industrial test in which a
short-circuit fault was detected is presented:

Power (kW) 220

Voltage (V) 380
Nominal Current (A) 387
Pole pairs 1
Nominal speed (rpm) 2965
Motors specifications

Figures 8 and 9 shows the normalized FFT of measured

current for two phases of the tested motor.
Fig. 7. FFT of the initial condition for short-circuits.

Fig. 8. FFT of measured current around short-circuit failure.

Fig. 8. FFT with 4.41% of short-circuits.

TABLE II
RESULTS OF SHORT-CIRCUITS
Frec (Hz) Amp (%) SC (%)
25.37 6,554 0
25.37 6,563 1,5
25.37 7,279 2,45
25.37 8,669 4,41

8,5
Amplitude (%)

7,5

7 Fig. 8. FFT of measured current around short-circuit failure.

6,5
0 1 2 3 4 5 In this particular case, it is no necessary to see the time-
Short-Circuit (%) evolution of the failure, due to the obviously differences
between spectrums of different motor phases.
Fig. 9. Short-Circuits fault evolution.
VII. CONCLUSIONS
A new methodology for monitoring and diagnosis of large
asynchronous motors is presented here. This methodology
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gives encouraging results. It is possible from this technique to
determine the exact extent of the defect and the associated
frequency. In this way, the study of the growth tendencies of
failures is easier.
VIII. ACKNOWLEDGMENT
Juan Pablo Fossati (M’2008) was born in
Montevideo, Uruguay on December 22, 1983. He
received the degree of Engineer from the
University of Montevideo in 2008, and now he is
currently working in the electrical motors research
group in the research institute (CITEM) of the
University of Montevideo.

The authors gratefully acknowledge the Technological

Development Program (PDT) of the Ministry of Education and
Culture of Uruguay. Marcelo Castelli and Juan Pablo Fossati
Marcos Andrade (M’1988 SM’1991) was
also thanks to ALFEX S.A. for their contribution in this born in Montevideo, Uruguay on August 4, 1949.
project. He received the degree of Electrical Engineer from
the Universidad de la República, in 1975, and now
he is currently working in the electrical motors
IX. REFERENCES research group in the research institute (CITEM)
[1] Thomson, W.T.; Gilmore, R. J. Motor Current Signature Analysis to of the University of Montevideo, and in ALFEX
Detect Faults in Induction Motor Drives- Fundamentals, Data S.A. as General Manager.
Interpretation, and Industrial Case Histories. Proccedings of 32rd
Turbomachinery Symposium, 2003.
[2] Thomson, W.T. A Review of On-Line Condition Monitoring
Techniques for Three-Phase Squirrel-Cage Induction Motors – Past,
Present and Future, The Robert Gordon University, Schoolhill,
Aberdeen, Scotland, 1999
[3] Kilman, G.B.; Premerlani, W.J.; Yazici, B.; Koegl, R.A.; Mazereeuw, J.
Sensorless, Online Motor Diagnostics, IEEE Computer Applications in
Power, April 1997
[4] Demian, C.; Mpanda-Mabwe, A.; Heano, H.; Capolino, G. Detection of
Induction Machines Rotor Faults at Standstill Using Signals Injection.
IEEE Trans on Ind Applications, Vol. 40 No 6, November/December
2004
[5] Legowski, S.F.; Ula, S.H.M.; Trzynadlowski, A.M. Instantaneous Power
as a Medium for the Signature Analysis of Induction Motors. IEEE
Trans. on Ind. Applications, Vol. 32, No 4, July/August 1996.
[6] Thomson, W.T.; Fenger, M. Case Histories of Current Signatura
Analysis to Detect Faults in Induction Motor Drives. Electrical
Machines and Drives, IEMDC IEEE, Volume 3; pp1459-1465, June
2003.
[7] Botha, M. M. Electrical Machines Failure, Causes and Cures, Electrical
Machines and Drives. 8th annual conference of IEEE, Nº 444, pp. 114-
117, 1-3 de September of 1997
[8] Bellini, A. Filippetti, F. Frabceschini, G. Tassoni, C. and Kliman, G. B.;
Quantitative Evaluation of Induction Motor Broken Bars by Means of
Electrical Signature Anlysis. IEEE Trans. on Ind Applications, Vol. 37,
Nº 5, September/October 2001
[9] Stack, J.R.; Habletler, T.G.; Harley, R.G. Bearing Fault Detection via
Autoregressive Stator Current Modeling. IEEE Trans. on Ind.
Applications, Vol. 40, Nº. 3, May/June 2004.
[10] Pereira, L.A.; da Silva Gazzana, D.; Pereira L. F. A. Motor Current
Siganture Analysis and Fuzzy Logic Applied to the Diagnosis of Short-
Circuit Faults in Induction Motors. IEEE 2005.

X. BIOGRAPHIES

Marcelo Castelli (M’2006) was born in

Montevideo, Uruguay on February 4 1979. He
received the degree of Engineer from the University
of Montevideo in 2004, and now he is currently
working toward PhD degree from the University of
Navarra (Spain) in the field of electrical machines.
After two years of research in TECNUN
(Technological Campus of the University of
Navarra), form 2004 to 2006, he came back to
Uruguay to work in the research institute (CITEM) of the University of
Montevideo. He is currently involved in the development of predictive
maintenances systems, and energy savings control systems. Also, he is the
Uruguayan PES Chapter Chair.