2011 IEEE International Electric Machines & Drives Conference (IEMDC)
Induction Motor Condition Monitoring: Vibration
Analysis Technique - a Practical Implementation
Mikhail Tsypkin
Vibration Specialty Corporation (VSC)
100 Geiger Road, Philadelphia, PA 19115-1090, USA
mtsypkin@vib.com
Abstract— Vibration analysis is one of the most successful
techniques used for condition monitoring of rotating machines.
The aim of this presentation is to show that vibration analysis is a
very efficient and convenient tool for diagnosing mechanical and
electromagnetic problems in induction motors. This presentation
is based on thirty-five years of the author’s experience in the field
of vibration motor diagnostics. Case histories from VSC’s field
service files covering assorted industries represent typical
mechanical and electromagnetic problems found in motors by
using vibration analysis techniques. Among them are: bearing
failure, mechanical imbalance, structural resonance and
foundation problems, winding damage, voltage waveform
distortion, faulty control of Variable Frequency Drives (VFD),
and combinations of mechanical and electrical problems. A short
theoretical analysis of electromagnetic excitation forces based on
classical electrical machinery theory is presented. A comparison
of the advantages and disadvantages of the varied modern
techniques used or recommended in today’s industry for
electrical motor condition monitoring is provided. The place of
vibration analysis in the realm of expert systems for motor
condition monitoring is also discussed.
Keywords - induction motors; condition monitoring; vibration
analysis; diagnostics; mechanical faults; electrical faults
I. INTRODUCTION
Condition monitoring and fault diagnosis of different kinds
of machines, including electrical machinery, have received
considerable attention in the last 40 years. Hundreds of
publications regarding induction motor condition monitoring
have been presented around the world in the last two decades.
Condition monitoring of electrical motors is a high-priority
task due to the prevalent and continually extended use of
electric motors around the world. The motor condition
monitoring science is moving toward an automated
computerized scheme, trying to remove human experts from
the condition monitoring process. “However, the development
of artificial intelligence for electrical machine condition
monitoring is still in its infancy and despite the considerable
work that has been done in this area, much more is required to
bring such techniques into the mainstream of condition
monitoring.” [1]. The aim of this presentation is to utilize the
findings of many years’ experience in the field of vibration
diagnostics on electrical machines from different industries to
create the most effective condition monitoring programs.
978-1-4577-0061-3/11/$26.00 ©2011 IEEE
Vibration analysis is one of the oldest and the most
successful techniques used for condition monitoring of
rotating machines. In combination with other non-invasive
techniques, it is used in all types of industry. Recently, some
experts have attempted to replace this technique for electrical
motor applications by using the motor current or other
electrical parameters for analysis. Practical experience
suggests that combining these techniques will provide greater
success in wider industrial use for electrical machines in the
near future.
Machine condition monitoring and fault diagnostics may be
defined as the field of technical activity in which selected
physical parameters, associated with machinery operation, are
observed for the purpose of determining machinery integrity
[2]. Vibration analysis of electrical machines is comprised of
two types of information: 1) vibration condition, which is
usually evaluated with regard to special standards or
specifications; and 2) data analysis, which allows for
diagnosing of mechanical and electromagnetic problems in
machinery, but these are not always related to excessive
machine vibration. In the process of vibration analysis, the first
of these tasks is called fault detection and the second one is
fault diagnosis. Fault detection is when a measurement
parameter exceeds a normal operating range. Fault diagnosis is
often associated with condition monitoring, and focuses on
specific changes and symptoms in order to determine a cause,
severity, and corrective action [2]. Many powerful signal
processing techniques can be applied to vibration signals for
the purpose of extracting even very weak fault indications from
noise and other masking signals [3].
II. SOURCES OF VIBRATION IN INDUCTION MOTORS
It is very important to realize that vibration signals are
always a compound of forcing function effects (the source)
and transfer function effects (the structural transmission path).
There are two major types of vibration sources in induction
motors: mechanical – typical of all rotating machines and
electromagnetic – specific to electrical machinery and for
induction motors in particular.
A. Vibration of Mechanical Origin
The major vibration sources of mechanical origin in
rotating machines, including induction motors, are: a rotor
imbalance, shaft bow and misalignment, and discrepancies in
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bearing operations as well as in the conditions of couplings,
sheaves, belts and other mechanical rotating elements of the
assembly. Mechanical looseness, foundation problems, and/or
structural resonances may significantly change vibration signal
amplitudes and configurations. Complete information about
mechanical sources of the vibration in rotating machines may
be found in [6]–[9].
B. Vibration of Electromagnetic Origin
Electromagnetic vibration in induction motors is a result of
effects of the electromagnetic forcing functions onto the motor
rotor and stator. Electromagnetic noise in induction motors has
been associated with vibration and studied since the early
designs of industrial motors. The first research in this field
was done in 1920’s and 1930’s [10] – [14].
There are two major sources of electromagnetic vibration in
induction motors: radial electromagnetic forces and tangential
electromagnetic forces. Well designed, normally operating
modern induction motors do not have a significant amount of
variable components of electromagnetic forces. However, due
to internal motor faults or external issues, such as low power
supply quality and type of load, electromagnetic vibration may
create serious problems to a normal motor’s operation.
A classical theory of electromagnetic vibration
mathematically describes radial electromagnetic forces as a
force-wave expression [15], [16]:
p(α,t) = P(r,ω) cos(rα - ωt - ψp) (1)
where P(r,ω) - The force-wave amplitude;
r - The force-wave order (mode);
ω - The force-wave angular frequency;
ψp - The phase angle;
α - An angular coordinate;
t - Time.
The force-wave is defined by the amplitude, frequency and
order (mode). The order of the force-wave is a number of full
waves distributed along the stator core circumference. Stator
core natural frequencies depend on the order of the force-wave.
Tangential electromagnetic forces may create significant
torque pulsation in an induction motor under certain
conditions. One of the first publications that pointed to the
relationship between the torque pulsation and motor vibration
was published in 1930 [11]. “A torsional vibration of the stator
and rotor as a whole results from periodic torque pulsation.
Such a vibration may be particularly objectionable as it is
transmitted directly through the motor feet to the supporting
structure. Due to the reaction of unsymmetrical supports
torque pulsation may also distort the stator from its circular
shape.” [11].
The periodic torque component is superimposed on the
constant torque component and causes torque pulsation. In
turn, torque pulsation results in undesirable speed pulsation,
noise, and vibration.
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A harmonic (periodic) component of electromagnetic
torque is defined as:
T(t) = T(Ω) cos(Ωt - ψτ) (2)
where T(Ω) - The harmonic torque component amplitude;
Ω - The angular frequency;
ψτ - The phase angle.
References [20] – [23] give a detailed theoretical analysis of
vibration in induction motors operating with torque pulsation.
III. CASE HISTORIES
Induction motor vibration is a result of a motor structure
excitation under the action of a forcing function of either
mechanical or electromagnetic origin. All discrepancies in the
motor’s operation are reflected in the vibration signal recorded
on the induction motor during its normal operation. Vibration
analysis extracts specific information from the data that
precisely identifies mechanical problems, such as: imbalance,
sheave and coupling misalignment, mechanical looseness,
bearing condition, foundation problems, resonances, etc..
Motor vibration data also contain substantial analytical
information about internal motor electrical issues, such as:
stator and rotor winding and core condition and air gap
eccentricity, as well as information about external electrical
problems: current/voltage imbalance, voltage distortions in the
power line, etc. All figures (spectra) in this section have their
axis labels identified as follows: The horizontal axis shows
frequency in cycles per minute (cpm). The vertical axis in the
regular spectra displays peak vibration amplitude (velocity) in
inches per second (ips). The vertical axis in the envelope
spectra is labeled as FEGs (Filtered Envelope G’s).
Case History #1
This was a 400-horsepower, 4-pole induction motor (direct
drive fan with two pillow block bearings) driven by a Variable
Frequency Drive (VFD). Spectra measured on the inboard
motor bearing during a standardized monthly survey (Fig. 1)
showed multiples of bearing defect frequency in the high
frequency range, especially between the 10th and 50th
harmonics. An envelope spectrum (Fig. 2) measured on the
inboard motor bearing contained multiples of a bearing defect
frequency with high modulation indexes. Regular and
envelope spectra indicated severe inboard motor bearing
damage [17], which was very likely a result of electrical
fluting. A faulty drive motor bearing was replaced. Vibration
data recorded after a new bearing was installed (Fig. 3 and Fig.
4) did not show any remaining vibration problem on the unit.

Figure 1. A regular vibration spectrum recorded on a drive motor bearing
indicated severe bearing deterioration, likely due to fluting.
Figure 2. An envelope spectrum recorded on the drive motor bearing
displayed severe bearing deterioration.
Figure 3. A regular vibration spectrum recorded on the drive motor bearing
after installation of a new bearing indicated acceptable vibration
levels.
Figure 4. An envelope spectrum recorded on the drive motor bearing after a
new bearing was installed no longer indicated any peaks.
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Case History #2
This was a variable speed, direct drive fan with an impeller
installed directly on the motor shaft. The 25-horsepower motor
was running at 3525 rpm during the testing. The highest
vibration peak amplitude of 0.70 ips at 3525 cpm was found
on the inboard motor bearing in the horizontal direction (Fig.
5). This peak vibration amplitude was significantly above
acceptable vibration levels. Vibration amplitudes in the two
other directions at 1X operating speed were below 0.05 ips
(Fig. 6). This vibration was very likely a result of a minor
impeller imbalance and a strong resonance condition on the
motor structure in the horizontal direction. A resonance (bump)
test revealed a natural frequency on the motor at 3540 cpm in
the horizontal direction (Fig. 7). The close proximity of the
motor’s running speed (3525 cpm) with a natural frequency
(3540 cpm) created a resonance condition on the motor, which
produced extremely high vibration that caused the bearings to
wear prematurely. Regular and envelope spectra (Fig. 8)
recorded on the motor bearings contained multiples of bearing
defect frequency, an indication of severe bearing deterioration.
The motor required a bearing replacement and the addition of
structural (motor base) stiffness in the horizontal direction to
raise the motor’s natural frequency and reduce the elevated
resonant vibration which rapidly wore down the bearings.
Figure 5. This regular vibration spectrum recorded on the drive motor bearing
in the horizontal direction indicated a high peak at 1X operating
speed (strong imbalance) and a bearing deterioration.
Figure 6. This regular vibration spectrum recorded on the drive motor bearing
in the vertical direction displayed a low peak at 1X operating speed
and bearing deterioration.

Figure 7. A resonance (bump) test was performed on the motor in the
horizontal direction which revealed the presence of a natural
frequency at 3540 cpm.
Figure 10. Vibration data recorded on the Chiller after the motor rotor
replacement.
A full set of twice slip frequency sidebands around the running
speed harmonics in the vibration spectra was a result of the
speed pulsation due to asymmetry of the rotor. The sideband
amplitudes were dependent on the severity of the asymmetry
in the rotor and the magnitude of speed pulsation, which
resulted from the periodic torque component and rotor inertia
[22].

Case History #4
A 60-horsepower, 4-pole induction motor with a belt driven
Figure 8. An envelope spectrum recorded on the drive motor bearing
fan was operating on a VFD and exhibited high vibration (Fig.
indicated severe bearing deterioration. 11). This excessive vibration was eventually determined to be
the result of a faulty VFD. The highest vibration peak of 0.54
ips at 3600 cpm (1X line frequency) disappeared (Fig. 12),
when the motor was operated directly from the power line (by-
Case History #3 passing the VFD). This was a sign of a severe distortion in the
motor’s input voltage when the VFD was in operation.
This case involved a 350-horsepower, 2-pole induction
motor that was enclosed in a Chiller. The unit, installed in a
hospital’s mechanical room on the ground floor, produced
excessive low frequency vibration, which interfered with
nearby medical equipment. Low frequency modulation in the
vibration data was a result of a motor rotor bar problem (Fig.
9). The 2X slip frequency sideband peaks surrounding the
running speed harmonics indicated a severe rotor bar problem
[18], while the high vibration amplitude at 1X running speed
signalled a strong rotor imbalance.
The motor rotor was finally replaced and the problem was
resolved – the 1X running speed amplitude was reduced to an Figure 11. This vibration spectrum was recorded on the motor operating from
the VFD at 60 Hz of controller output frequency.
acceptable level and the 2X slip frequency sidebands
disappeared (Fig. 10).

Figure 12. This vibration spectrum was recorded on the motor while it
Figure 9. Vibration data recorded on the faulty Chiller. operated directly from the regular power line (while bypassing the
VFD).

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An excessive motor vibration at line frequency harmonics
while operating with a VFD usually results from a voltage
distortion on the motor [20] - [22]. In this particular case, high
vibration levels were found at 1X line frequency (3600 cpm),
which is very unusual for induction motors. It is very likely
that the output voltage/current on the faulty VFD controller
contained a direct current (DC) component during the testing.
Only the DC current component in the motor winding and the
rotating magnetic field may create a periodic torque
component at 1X line frequency (3600 cpm or 60 Hz). A Figure 15. This vibration spectrum was recorded on the motor
pulsating torque with the 1X line frequency harmonic was the on June 20, 2003.
source of the extremely high vibration present across the
whole unit.

Case History #5
Vibration data was collected during 10-years of monitoring
a 10,000-horsepower pipeline compressor motor with a rotor
bar problem, developing in stages from incipient damage to a
vibration fault, which eventually required motor replacement
[24].
Figure 16. This vibration spectrum was recorded on the motor
on September 11, 2008.
Initially, the problem was only minor and did not have any
effect on the motor’s performance (Fig.13, Fig. 14 and Fig.15).

Over time, the vibration spectra clearly showed the

condition to be degrading (Fig. 16) which culminated in a
dramatic change in the rotor’s balance condition (Fig. 17).

The motor was replaced in March, 2010 and vibration

levels have since returned to acceptable amplitudes with
respect to vibration severity (Fig. 18).
Figure 17. This vibration spectrum was recorded on the motor
on September 2, 2009.

Figure 13. This vibration spectrum was recorded on the motor on

December 13, 2000.
Figure 18. This vibration spectrum was recorded on the motor
on March 12, 2010 after a new motor was installed.

This case study demonstrated that induction motors with

rotor bar issues can operate for years without any harm to the
machine or its performance. As they were monitored over
time, vibration levels dramatically increased on the motor as a
result of a mechanical imbalance due to missing material in
the motor rotor, with damaged rotor bars and shorting rings.
The use of vibration analysis was crucial for investigating the
Figure 14. This vibration spectrum was recorded on the motor severity of the motor’s problem and was also critical in
on October 11, 2001.
determining the proper time to conduct the replacement.

410
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