Journal

of Energy VOLUME 67 Number 3 | 2018 Special Issue

journal homepage: http://journalofenergy.com/

Application
Ante Elez, PhD*
Josip Študir, M.E.E.*
Stjepan Tvorić, M.E.E.**

of Differential
*KONČAR – Generators and Motors
**KONČAR – Electrical Engineering Institute
CROATIA

Magnetic Field
Measurement
(DMFM method)
in winding fault
detection of
AC rotating
machines as
part of expert
monitoring
systems
SUMMARY
Stator and rotor winding damages in rotating machines are result of electrical, mechanical, and thermal stress. Online magnetic field monitoring via
permanently installed measuring coils inside air gap is a well-established methodology which enables winding fault detection. The paper deals with a
new method for detection of stator and rotor winding inter-turn short circuits of synchronous machines and slip rings induction machines, as well as
rupture of rotor bars and cage ring of induction machines. The method novelty is based on differential measurement of magnetic field by using two
serial connected measuring coils. They are installed on the places (stator or rotor teeth) in the machine which have, by absolute value, equal magnetic
vector potential. The distance between the measuring coils is n·p, where p is a pole pitch, and n = 1, 2, 3, 4,... is a multiple of the pole pitch. Measuring
the coil-induced voltage enables us to detect stator and rotor winding faults, which means that measured voltage is approximately zero without fault
and increases in the presence of fault. Analysis of the measuring signal allows us to detect and locate fault. With this new method it is possible with
high sensitivity to determine winding fault, which enables more reliable fault detection. For example, in comparison with the motor current signature
analysis method (the most widely used method for motor faults detection), this new method gives 200 times higher sensitivity to fault occurrence.
Also, by using the DMFM method, faults can be detected in the time domain and there is no need for spectral or other complex signal analysis. This
is very important because the measuring equipment used for machine fault detection can be simple and more economically acceptable. The DMFM
method enables fault detection for even small machines with small expense in a very effective way. The only downside of the DMFM method is the
fact that machine should be disassembled in order to install measuring coils. This problem is solved during the machine overhaul or during the manu-
facturing of the machine, when sensors can be easily implemented in the machine. For machines with large air gap, measuring coils can be installed
without a machine disassembly. For the purpose of the method testing, numerous finite-element (FE) simulations on the 2- and 3-D machine models
have been carried out to verify the method. Powerful numerical tools generate realistic results with properly selected starting and boundary conditions.
By FEM models, actual machines with embedded measuring coils where created and simulated. The voltage induced inside the measuring coils is
calculated for different machine states, load point and with and without a fault (broken rotor bar or inter-turn short circuit). Also, this method was expe-
rimentally validated via series of laboratory tests performed on the real electric machines specially designed for fault study (broken rotor bars, broken
ring and inter-turn short circuits in a stator and rotor winding). Additionally, this method is applied on more than 20 real machines in industry. Due to
the large amount of measured data, in this paper, it will be presented only one measurement performed on an induction motor on which we have

A. Elez, J. Študir, S. Tvorić, Application of Differential Magnetic Field Measurement (DMFM method) in winding fault detection of AC rotating machines as
3 part of expert monitoring systems, Journal of Energy, vol. 67 Number 3 (2018), Special Issue, p. 7–12
 detected one broken rotor bar. The thickness of the measuring coil designed in the printed circuit board technique is 0.3 mm. The number of turns
is from 3 to 10. This new method and performed FEM calculations together with the experimental measurements improve fault detection portfolio
knowledge that can be used in monitoring and diagnostics of rotating machines. Furthermore, this patent-pending method is already implemented in
three innovative products placed on market (expert monitoring systems), so this method is fully confirmed in practice.

KEYWORDS
finite element, induction machine, inter-turn shorted circuits, rotor bars, rotor cage faults, synchronous generator, magnetic field, measuring coil,
induced voltage, air gap

INTRODUCTION The measuring coils 1 and 2 must be installed to such locations in the
machine that
Figure have the coil
2. Measuring same magnetic
in PCB vector
technique potential
installed by absolute
on the stator tooth value.
Stator and rotor winding damages in rotating machines are result of electri- To meet this requirement and realize the measurement method, it is ne-
cal, mechanical, and thermal stress. Online magnetic field monitoring The via measuring
cessary coils
to 1connect
and 2 mustthebemeasuring
installed to such
coilslocations
1 and 2inwiththe machine
each otherthat have the same
in series
magneticdepending
vector potential by absolute
on the parity ofvalue.
the To meet this
multiple requirement
of the and realize
pole pitch . the measurement
permanently installed measuring coils inside air gap is a well-established p
method, it is necessary to connect the measuring coils 1 and 2 with each other in series depending on
methodology which enables winding fault detection [1, 2, 3, 4, 5]. In the theparity of the multiple of the pole pitch τp.
INTRODUCTION industry and according to the literature [6, 7, 8, 9], rotor winding faults are
If an odd multiple of n=1, 3, 5, 7… of the pole pitch p is chosen for the
distance between the measuring coils, then the measuring coils 1 and 2
very common problem. Most commonly used method for detection of bro- If an odd multiple of n=1, 3, 5, 7… of the pole pitch τp is chosen for the distance between the
Stator and rotor winding damages in rotating machines are result of electrical, mechanical,measuring should
and thermal be connected as shown in Figure 3.
ken rotor bars is method based on current signature analysis (MCSA) [10, coils, then the measuring coils 1 and 2 should be connected as shown in Figure 3.
stress. Online magnetic field monitoring via permanently installed measuring coils inside air gap is a
11, 12, 13, 14, 15, 16, 17].
well-established methodology which enables winding fault detection [1, 2, 3, 4, 5]. In the industry and
1 2
according to The
the literature
novelty of [6,DMFM
7, 8, 9],method
rotor winding faults aremeasurement
is differential very common of problem. Most commonly
the magnetic 2.1
1.2
used methodfield
for detection of broken
in a rotating rotor with
machine bars is method
two serialbased on current
connected signaturecoils,
measuring analysis
in- (MCSA) 1.1
[10, 11, 12, 13, 14, 15,
stalled on16,
the17].
places in the machine which have, by absolute value, equal 2.2
The novelty of DMFM method is differential measurement of the magnetic
magnetic vector potential. The distance between the measuring coils is field in a rotating machine np
with two serial
n∙pconnected
, where pmeasuring coils, installed
is a pole pitch, and n=1,on2, the3, 4places
… is in the machine
a multiple of thewhich
polehave, by
absolute value, equal
pitch. magnetic
A typical vector potential.
installation The distance
of measuring between theinmeasuring
coils is presented Figure 1. Me-coils is n·τp, n=1, 3, 5, 7…
where τp is aasuring
pole pitch,
coilsand n=1,2 2,
1 and are3,installed
4 … is aaround
multiplestator
of thetooth
pole so
pitch.
thatAthey
typical installation of
encom-
measuring coils
passis the
presented
wholeinstator
Figure 1. Measuring
tooth or just partcoils 1 and
of the 2 are installed around stator tooth so
tooth.
that they encompass the whole stator tooth or just part of the tooth.
3

Figure 3. Typical measuring sensor installation if an odd multiple of the pole pitch is chosen for the
Figure 3. Typical measuring sensorthe
distance between installation
measuringif coils
an odd multiple
1 and 2. of the pole pitch is
chosen for the distance between the measuring coils 1 and 2.
The inner side (pos.1.1 Figure 3) of the coil 1 connects with the inner side 2.1 of the coil 2. The outer
TheFigure
side (pos.1.2 inner 3)
side (pos.1.1
of the coil 1, Figure
through 3) of the coil
measuring 1 connects
system with3),the
(pos.3 Figure inner with
connects sidethe
2.1
outer side of theFigure
(pos.2.2 coil 3)
2.ofThe outer
the coil sidemeasuring
2. The (pos.1.2coils
Figure
1 and3)2 connected
of the coil 1, through
in series according
2
to Figuremeasuring system
3, whose mutual (pos.3
distance is an Figure 3), connects
odd multiple n=1, 3, 5, 7…withofthe outer
the pole side
pitch τp, (pos.2.2
will have the
np same absolute
Figure 3) of
value of athe coil 2.field,
magnetic Thebutmeasuring
the directioncoils
of the1magnetic
and 2 connected
field lines willinbeseries
different.
The measuring coils connected
according to Figureand installed mutual
3, whose in this way allow mutual
distance is ansubtraction
odd multipleof then=1,
voltages
3, 5,that
are induced
7…inofthethemeasuring coils 1 and
pole pitch , 2. have
will If an even
the multiple
same of n=2, 4, 6,
absolute 8… ofofthe
value a pole pitch τp is
magnetic
chosen for the mutual distance of the p measuring coils, then the measuring coils 1 and 2 should be
field, but the direction of the magnetic field lines will be different. The me-
connected as shown in Figure 4.
asuring coils connected and installed in this way allow mutual subtraction
of the voltages that are induced in the measuring coils 1 and 2. If an even 3
multiple of n=2, 4, 6, 8… of the pole pitch p is chosen for the mutual dis-
tance of the measuring coils, then the measuring coils 1 and 2 should be
connected as shown in Figure 4.

1 1 2
Figure 1. Principle of typical installation of measuring sensor on stator tooth: pos.1 measuring coil 1.2 2.1
Figure 1. Principle of typical installation of measuring sensor on stator tooth: pos.1
no. 21,measuring
measuring coil no. 1, pos. pos. 2 measuring
coil no.2.coil no.2. 1.1
2.2
np
The measuring Thecoils 1 and 2 coils
measuring are installed
1 and 2 onarethe stator tooth,
installed on theand thistooth,
stator way the
andarea
thisthrough
way which
magnetic fieldtheisarea
measured
through is which
strictlymagnetic
defined. With this
field is type of installation,
measured the areaWith
is strictly defined. on which a
magnetic fieldthisistype
measured is equal for
of installation, theboth
areameasuring
on which coils, which field
a magnetic is crucial for this differential
is measured is n=2, 4, 6, 8…
measurementequal
method. for both measuring coils, which is crucial for this differential mea-
In some cases, measuring
surement coils can encompass only a section of the stator tooth for machines with
method.
radial ventilation gaps, or two identical measuring coils can be installed in the same position on the
In some cases, 3
tooth. The measuring coils 1 measuring
and 2 are madecoilsincan
PCB encompass
technique, only a section
as shown of the
in Figure 2 stator
(installation on
tooth
the stator tooth forinduction
of the machines withinradial
motor ventilation
the real condition).gaps, or two identical measuring
coils can be installed in the same position on the tooth. The measuring Figure 4. Typical measuring sensor installation if an even multiple of the pole pitch is chosen for the
coils 1 and 2 are made in PCB technique, as shown in Figure 2 (installation Figure 4. Typical measuring sensor
distance installation
between if an even
the measuring coils 1multiple
and 2 of the pole pitch is
on the stator tooth of the induction motor in the real condition). chosen for the distance between the measuring coils 1 and 2
The inner side (pos.1.1 Figure 4) of the coil 1 connects with the outer side (pos.2.2 Figure 4) of the
Thecoilinner
2. The side
outer (pos.1.1
side (pos.1.2Figure
Figure 4)4) ofofthethe
coilcoil 1 connects
1, through measuringwith the(pos.3
system outer side4),
Figure
connects with
(pos.2.2 Figurethe inner
4) ofsidethe(pos.2.1
coil Figure
2. The 4) outer
of the coil 2. The
side measuring
(pos.1.2 coils 1 and
Figure 4) of2 connected
the coilin
series according to Figure 4, whose mutual distance is an even multiple n=2, 4, 6, 8… of the pole pitch
1,τpthrough
, will have measuring
the same absolute system
value of(pos.3
a magneticFigure 4), connects
field and withofthe
the same direction the inner
magneticside
field
(pos.2.1
lines. TheFigure
measuring 4)coils
of the coil and
connected 2. The
installedmeasuring coilsmutual
in this way allow 1 and 2 connected
subtraction in
of the voltages
series according to Figure 4, whose mutual distance is an even multiple n=2,4)
that are induced in the measuring coils 1 and 2. The measuring system (pos. 3 Figure 3 and
measures the total voltage U that is induced in two measuring coils 1 and 2, connected in series. In
4,simple
6, 8…application,
of the pole pitch can
this method , will have the same absolute value of a magnetic
p be used in a following way: if the measured voltage U exceeds a
field 2 and the
predefined same
value, directionsystem
the measuring of the canmagnetic field lines.
activate an output The signals
relay which measuring
the usercoils
that a
winding faultand
connected is present in the machine.
installed Figureallow
in this way 5 showsmutual
a simplified presentationof
subtraction of the
themagnetic
voltages field
line distribution in a four-pole induction machine along with possible locations for installation of
that are induced
measuring coils. in the measuring coils 1 and 2. The measuring system (pos.
3 Figure 3 and 4) measures theA total voltage U that is induced in two measu-
ring coils 1 and 2, connected in series. In simple application, this method can
be used in a following way: if the measured voltage U exceeds a predefined
value, the measuring system M can activate an output relay which signals the
user that a winding fault is present in the machine. Figure 5 shows a simplified
presentation of the magnetic B
field line distribution in Da four-pole induction
Figure 2. Measuring coil in PCB technique installed on the stator tooth machine along with possible locations for installation of measuring coils.
Figure 2. Measuring coil in PCB technique installed on the stator tooth
C

The measuring coils 1 and 2 must

A. Elez, be installed
J. Študir, to such
S. Tvorić, locations of
Application in Differential
the machineMagnetic
that haveField
the same
Measurement (DMFM method) in winding fault detection of AC rotating machines as
magnetic4vector potentialpart
by of
absolute
expertvalue. To meet
monitoring this requirement
systems, Journal ofand realize
Energy, the67measurement
vol. Number 3 (2018),
FigureSpecial Issue,
5. Simplified p. 3–8 of the magnetic field line distribution along with possible locations
presentation
method, it is necessary to connect the measuring coils 1 and 2 with each other in series depending on for magnetic field installation
the parity of the multiple of the pole pitch τp.
 measures the total voltage U that is induced in two measuring coils 1 and 2, connected in series. In
simple application, this method can be used in a following way: if the measured voltage U exceeds a
predefined value, the measuring system can activate an output relay which signals the user that a
winding fault is present in the machine. Figure 5 shows a simplified presentation of the magnetic field
line distribution in a four-pole induction machine along with possible locations for installation of
measuring coils.
A Figure 6 and Figure 7 present the magnetic field line distribution in the
cross section of the induction machine with and without broken rotor bars
acquired by FEM simulations. On Figure 7 machine cross section zone
M where rotor broken bars effect can be noticed is marked by white dashed
B D
presentsline. Figurevoltage
calculated 8 presents
waveformcalculated voltage
induced in waveform
two measuring coilsinduced in in
connected two mea-
series and installed
suring
around stator coils
tooth connected
without inwith
fault and series
oneand installed
broken around stator tooth without
rotor bar.
fault and with one broken rotor bar.
presents calculated voltage waveform induced in two measuring coils connected in series and installed
C around stator tooth without fault and with one broken rotor bar.

Figure 5. Simplified presentation of the magnetic field line distribution along with possible locations presents calculated voltage waveform induced in two measuring coils connected in series and installed
around stator tooth without fault and with one broken rotor bar.
Figure 5. Simplified presentationforofmagnetic field installation
the magnetic field line distribution along with
possible
Positionslocations for magnetic
for installation field
of measuring installation
coils in a four-pole machine, at a mutual distance of multiple
pole pitch n·τp, where n=1, 2, 3, 4, 5, 6, 7…, marked by positions A, B, C and D as presented in Figure
Positions for installation
5, have by absolute of measuring
value equal magnetic coils
potential for in a four-pole
one selected machine,
time point. However, at a
the direction
mutual distance
of the magnetic field of
linesmultiple pole5) pitch
(pos. M Figure n·p, where
on the observed positionsn=1,
is not 2,
the 3, 4, but
same, 5, it6,differs
7…,on
the positions A and C in relation to positions B and D. If the pole pitch τp or odd multiple of pole pitch
marked by positions A, B, C and D as presented in Figure 5, have by abso-
lute value equal magnetic potential for one selected time point. However,
the direction of the magnetic field lines (pos. M Figure 5) on the observed4
positions is not the same, but it differs on the positions A and C in relation
to positions B and D. If the pole pitch p or odd multiple of pole pitch p is Figure 6. Presentation of the magnetic field line distribution in the cross section of four pole induction
chosen as a mutual distance of the measuring coils during their installation Figure 6. Presentation of the magnetic machine
fieldwithout
line broken rotor bars.
distribution in the cross section of four pole induction
in the machine, then the measuring coils 1 and 2 should be installed at Figure 6. Presentation of the machine without
magnetic fieldbroken rotor bars.
line distribution in the cross section of
Figure 6. induction
Presentation machine
of the magnetic field line distribution
rotorinbars.
the cross section of four pole induction
the positions A and B or A and D or C and B or C and D; and connected four pole without broken
machine without broken rotor bars.
according to Figure 3. If an even multiple pole pitch p is chosen as a mu-
tual distance of the measuring coils during their installation in the machine,
then the measuring coils 1 and 2 should be installed at the positions A
and C or B and D and connected according to the Figure 4. In the case
of a normal machine operation, in the measuring coils 1 and 2 installed in
the corresponding places in the machine and connected according to the
n as a mutualFigure
distance3 orofFigure
the measuring
4, the same coils duringwill
voltage their installation
be induced dueintothethemachine,
changingthen
ring coils 1 and 2 should
magnetic be of
field installed at the positions
the machine. Therefore, A inand
theBcaseor Aofand D or Cmachine
a normal and B or C
d connected according
operation to (noFigure
fault), 3.theIftotal
an even multiple
voltage of twopole pitch τpcoils,
measuring is chosen as a mutual
connected in
f the measuring coils isduring
series, their installation
approximately equal to in zero
the machine,
for eachthen the measuring
selected time during coilsone 1 and Figure 7. Presentation of the magnetic field line distribution in the cross section of four pole induction
machine with broken rotor bars.
e installed at turn
the positions A and CInorcase
of the machine. B and D andwinding
of rotor connected according
damage, and at to the
the moment
Figure 4. In
f a normal machine operation,
of the arrival of the in damaged
the measuring rotorcoils
winding1 and on2oneinstalled
of theinmeasuring
the corresponding
coils U[V]
Figure 7. Presentation
4
of the magnetic field line distribution in the cross section of four pole induction
he machine and 1 and connected according
2, the voltages thatto are
the induced
Figure 3inorthe Figure 4, the same
measuring coils 1voltage
and 2 will will be 3
machine with broken rotor bars. 1

ue to the changing magnetic

no longer field of
be equal. the machine.
Thus, Therefore,
the total voltage of twoin the case of acoils
measuring normalconnec- machine Figure 7. Presentation of the magnetic field line distribution in 2 the cross section of
Figure 7.four
Presentation 4 of the magnetic field line distribution in the cross section of four pole induction
2
U[V]
pole induction machine with broken rotor bars.
(no fault), theted in series
total voltagewillofnot twobemeasuring
equal to zero coils,forconnected
any chosen moment
in series, is during one
approximately 1 machine with broken rotor bars.
turn of the
ero for each selected timemachine.
during one By measuring
turn of the the total voltage
machine. In caseof oftwo
rotor measuring
winding damage,coils 3 1
2
0
moment of the connected
arrival of intheseries
damaged during onewinding
rotor turn of the machine,
on one of the one can unambiguo-
measuring coils 1 and 2, 2 0 5 10 15 20 25 30 35 40
U[V]
usly detect a rotor winding failure in induction and
es that are induced in the measuring coils 1 and 2 will no longer be equal. Thus, the total synchronous machines. 4 -1
1 t[ms]

two measuring In addition to winding

coils connected in failure detection,
series will not bethe number
equal to zeroof rotor
for any winding
chosen failures
moment 3
-2
0 1
can be determined
e turn of the machine. By measuring as well. By serial
the total voltageconnection of the measuring
of two measuring coils 1 in
coils connected -3
-1
0 5 10 15 20 25 30 35 40
2
t[ms]
ing one turn and 2, the magnetic onefield
canpresent in a machine operating
a rotorwithout
windingdamage
2
of the machine, unambiguously detect failure in -4
-2

and synchronousis eliminated

machines.from the measured
In addition value failure
to winding and thedetection,
measuredthevalue numberdepends of rotor 1
Figure 8. Calculated voltage induced in two measuring coils connected in series:
1 – with one broken rotor bar, 2 – without fault.
only on the magnetic field caused by rotor winding damage. The method -3

ailures can be determined as well. By serial connection of the measuring coils 1 and 2, the
for rotor winding damage detection was tested by numerical calculations 0 -4

ield present in a machine operating without damage is eliminated from the measured value 0 Figure 8. Calculated
5 10 15 in two 20
voltage induced 25 connected
measuring coils 30 in series:35 640
using Finite Element Method (FEM). Furthermore, the laboratory tests con-
easured valuefirmed
depends only on the magnetic field caused by
the effectiveness of this method through experiments on a synchro-rotor winding damage. The -1 1 – with one broken rotor bar, 2 – without fault. t[ms]
r rotor winding nousdamage
and an detection
induction wasmachine.
tested by numerical calculations using Finite Element -2 6
EM). Furthermore, the laboratory tests confirmed the effectiveness of this method through
ts on a synchronous and an induction machine. -3

-4

ALYSIS FEM ANALYSIS Figure 8. Calculated voltage induced in two measuring coils connected in series:
Figure 8. Calculated1 voltage
– with one broken
induced in rotor bar, 2 – without
two measuring fault.
coils connected in series:
urpose of the For the purpose
method of the method
testing numerous testing
two and numerous twomachine
three-dimensional and three-dimen-
models were 1 – with one broken rotor bar, 2 – without fault.
sional machine
owerful numerical modelsrealistic
tools generate were created.
results Powerful numerical
with properly tools starting
selected generateand 6
realistic results with properly selected starting and boundary conditions.
conditions. By FEM models, actual machines with embedded measuring coils where created By observing the waveform of voltage induced in two measuring coils
By FEM models, actual machines with embedded measuring coils where
ated. The voltage induced inside the measuring coils is calculated for different machine connected in series, presented in the Figure 8, the rotor winding damage
created and simulated. The voltage induced inside the measuring coils is
d point and with and without a fault (rotor bare rupture or inter-coil short circuit). Table 1 is easy to detect. The measuring voltage is sensitive only to machine fa-
calculated for different machine states, load point and with and without a ults. In the Figure 8, winding damage is marked with voltage peek, which
achine operating
faultconditions
(rotor barefor whichorcalculations
rupture are circuit).
inter-coil short performed.Table 1 presents machine is repeated two times during a full turn in the case of one broken rotor
operating conditions for which calculations are performed. bar. When the broken rotor bar comes across the measuring coil, one
Table.1. Machine operating condition for FEM calculations
Table.1. Machine voltage peak appears. Therefore, in the measured waveform during one
machine turn two extremely high voltage peaks will appear. Accordingly,
Without frequency

No. of simulations

operating
the number of such measured peaks of the measured voltage during one
With frequency
Decreased load

condition for FEM

Nominal load
Machine type

calculations full machine turn, divided by two, gives the number of broken rotor bars.
converter

converter

Similar results were calculated for a synchronous machine with inter-coil

Operating condition short circuit in excitation winding.
No

1 No fault • • • • 4
2 With one broken rotor • • • • 10
3 With
bar two broken rotor • • • • 20
MEASUREMENT RESULTS AND
Induction

4 With
bars five rotor broken • • • • 20
With
bars one broken rotor
5

6
bar and eccentricity
With two broken rotor
• • • • 20

20
APPLICATION
• • • •
bar and eccentricity
7 No fault • • 4
This method is verified experimentally via series of laboratory tests perfor-
8 With 1% or shorted • • 5 med on the real machines specially designed for fault study of broken rotor
Synchronous

9 With
turns 2 % of shorted • • 5 bars, broken ring and inter-coil short circuit in a rotor winding. Additionally,
10 With
turns 5% of shorted • • 3
With
turns 1% of shorted
this method is applied on more than 20 real machines in industry. Due
11 • • 10 to the large amount of measured data, in this paper we will present only
turns and eccentricity
With 2% of shorted one measurement performed on an induction motor on which we have
12 • • 10
turns and eccentricity
detected one broken rotor bar. The rating of the machines where method

nd Figure 7 present the magnetic field line distribution in the cross section of the induction
with and without 5 A. Elez,
broken rotor bars J. Študir,
acquired byS.FEM
Tvorić,simulations.
Application ofOn
Differential
Figure 7Magnetic
machineField Measurement (DMFM method) in winding fault detection of AC rotating machines as
cross
part ofcan
ne where rotor broken bars effect expert
be monitoring
noticed is systems,
marked Journal
by whiteof Energy,
dashedvol. 67 Figure
line. Number83 (2018), Special Issue, p. 3–8

5
measured peaks of the measured voltage during one full machine turn, divided by two, gives the
number of broken rotor bars. Similar results were calculated for a synchronous machine with inter-coil
short circuit in excitation winding.

MEASUREMENT RESULTS AND APPLICATION

as applied are: 15, 65, 725, 800, 1200, 1250 kW. The thickness of the
measuring
This method is coil designed
verified in the
experimentally via PCB technique
series of is 0,3
laboratory tests mm. on
performed The
thenumber of
real machines
speciallyisdesigned
turns from 3fortofault
10.study
Fromof broken
our rotor bars, brokenthe
experience ring1and inter-coil
turn short circuit
is enough to in a rotor
obtain
winding. Additionally, this method is applied on more than 20 real machines in industry. Due to the
good signals,
large amount but our
of measured practice
data, is to
in this paper weuse 10 turns.
will present only one measurement performed on an
induction motor on which we have detected one broken rotor bar. The rating of the machines where
Figure
method as 9 presents
applied are: the 15,measured
65, 725, 800,induced voltage
1200, 1250 kW. The at thickness
the endofofthe each measu-
measuring coil
ring coilinand
designed alsotechnique
the PCB on the isterminal of series
0,3 mm. The numberconnected
of turns is fromcoils
3 to for normal
10. From our operati-
experience
the 1without
on turn is enough
fault.toThe
obtain good signals,
voltage but our practice
waveform is to use
is periodic 10 turns.
and repeated for each turn
of the9machine,
Figure presents thewhich
measuredcorresponds
induced voltagetoatthe
the time
end ofof 40measuring
each ms, i.e. coil
4 pole pitches,
and also on the
i.e. 4p.ofIt series
terminal can be seen that
connected coils the difference
for normal voltage
operation withoutfor series
fault. The connected
voltage waveformcoilsis
periodic
are lessandthan
repeated
0.5forV each
for turn of the machine
healthy machine, which
andcorresponds
the induced to the time of 40 ms,
voltage i.e. 4 pole
waveform
pitches, i.e. 4τp. It can be seen that the difference voltage for series connected coils are less than 0.5 V
has the same
for healthy machine shape
and thefor the measuring
induced coil has
voltage waveform 1 and for the
the same shapemeasuring coil 2.coil 1
for the measuring
and for the measuring coil 2.
a)
Voltage induced in measuring coils - normal operation Voltage at the ends of the serial connected coils - normal operation
2
Coil No.1
2 Figure 11. a) measuring coil, b) FDSS (Fault Detecting Sma
broken bars and inter-coil short circuits
Voltage difference [No.1-No.2]
1,5 Coil No.2 1,5

1 1

0,5 0,5

More complex product in which this patent-pending method is

Vol tage [V]
Vol tage [V]

0 0
0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80

-0,5 -0,5
This product enables fault detection, determination of number o
be applied for induction machine but also for synchronous hy
-1 -1

-1,5 -1,5

-2
Time [ms]
-2
Time [ms]
can be permanent through an on-line measurement or users can
a) b) rotor winding faults.
Figure 9. Voltage induced in coils without fault: a) voltage induced in each measuring coil without
fault, b) voltage induced in series connected coils terminal
Figure 9. Voltage induced in coils without fault: a) voltage induced in each
measuring coil without
Figure 10 presents fault, induced
the measured b) voltage induced
voltage at the in
endseries connected
of each coilsand
measuring coil terminal
also on the
terminal of series connected coils for machine with one broken rotor bar. It can be seen that the
Figure
difference10 presents
voltage for seriesthe measured
connected coils areinduced voltage
now greater than 1.25at themachine
V for end of each
with me-
one broken
bar and could
asuring coilbeand
detected.
also on the terminal of series connected coils for machine
with one broken rotor bar. It can be seen that the difference voltage for
series connected coils are now greater than 1.25 V for machine with one
broken bar and could be detected.
7
a) Voltage at the ends of the serial connected coils - 1 broken rotor bar
Voltage induced in measuring coils - 1 broken rotor bar b)
Figure 11. a) measuring coil, b) FDSS (Fault Detecting Smart Sensor) enables detection of rotor
2 2
Coil No.1
Figure 11. a) measuring coil, b) FDSS (Fault Detecting Smart Sensor)
a) b)enables
Voltage difference [No.1-No.2]
1,5 Coil No.2 1,5

1 broken bars and inter-coil short circuits

detection of rotorin rotor
broken bars winding
and inter-coil short circuits in rotor winding
Figure 11. a) measuring coil, b) FDSS (Fault Detecting Smart Sensor) enables detection of roto
1

0,5
broken bars
More complex andininter-coil
product which thisshort circuits in method
patent-pending rotor winding
is implemen-
0,5
Vol tage [V]

Vol tage [V]

ted is presented in Figure 12. This product enables fault detection, deter-
More complex product in which this patent-pending minationmethod is implemented is presented inIt Figure 12. for
0 0
0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80

-0,5
More complex product inofwhich
number ofpatent-pending
this faults and also fault positions.
method can be applied
is implemented-0,5
is presented in Figure
-1This product enables fault detection, determination of number
induction
This product enables of
machine faults
but alsoand also fault
for synchronous positions.
hydro and turboIt can
machines.
fault detection, determination of number of faults and also fault positions. It
-1

Measurement can be permanent through an on-line measurement or

be applied for induction machine but also
-1,5
for synchronous
be applied for induction hydro but
users can machine and
periodically turbo
also
measure machines.
forinsynchronous
order Measurement
hydro
to locate rotor and turbo
-1,5

winding machines. Measurem

faults.
can be permanent through an on-line measurement can be permanent or users
throughcan periodically
an on-line measure
measurement or users in
canorder to locate
periodically measure in order to lo
-2 -2
Time [ms] Time [ms]

a) b) rotor winding faults.

rotor
Figure winding
10. Voltage faults.
induced in coils with one broken bar: a) voltage induced in each measuring coil
with fault, b) voltage induced in series connected coils terminal
Figure 10. Voltage induced in coils with one broken bar: a) voltage induced in each
Broken rotorcoil
measuring bar detection based
with fault, on the voltage
b) voltage waveform
induced induced
in series in one measuring
connected coil, as presented
coils terminal
in Figure 10.a), requires a complex signal processing. However, by observing the voltage waveform Figure 12. HG-WFD System (Hydro Generator W
induced inrotor
Broken two measuring coils connected
bar detection based in series,
on the as presented
voltagein waveform
Figure 10.b), one can conclude
induced that
in one
a rotor winding damage is easy to detect. The serial connection of two measuring coils cancels out a
measuring coil, as presented in Figure 10.a), requires a complex signal proce-
magnetic field present inside the machine without fault from the measuring signal. In that way two
ssing. However,
measuring by observing
coils connected thethe
in series measure voltage
magneticwaveform induced
field caused only by rotorinbroken
two bar.
measu- The concept of the EMCM system (Expert Machine Condition
ring
Fromcoils
Figureconnected in series,
10 it can be seen as presented
that the voltage in Figure
peaks amplitude, caused10.b),
by rotorone can
broken conclude
bar,
1 V and 1.25 V. This level of signal is a sufficient for reliable damage detection and there is no need
is between This system is specially designed for condition monitoring of
that a rotor winding damage is easy to detect. The serial connection of two
for amplification of the measured signal. This method, besides for broken rotor bar detection, can be
measuring coils cancels
used for determination out a ofmagnetic
of the number the broken field present
bars, but also forinside the machine
determination wit-
of their mutual
shows the web interface of the EMCM system. Through this
hout faultFrom
positions. from the measuring
Figure 10 it can be seensignal. Involtage
that the that wayof twotwo measuring
measuring coils connec-
coils connected in series, relevant parameters of the induction motor, such as curren
for the rotor part without any winding damage, is not equal to zero. This occurs due to allowed
ted in series measure the magnetic field caused only by rotor broken bar.
tolerances in the machine manufacturing and assembly and imperfections of measuring coils temperatures, and especially the condition of the squirrel-c
installation. However, one can clearly see the change in the value of the measured voltage in the case
From
of rotorFigure 10 which
broken bar, it canisbe seen
almost 150%that
for the voltagemachine.
the presented peaksThe amplitude, caused
method has been tested by
for winding (with or without fault) is monitored by application of t
rotor broken bar, is of
between 1 and
V and 1.25 V.detects
This level of signal is in
a suffici-
the entire
operating
operating
range. The
range
method
the machine
has been tested
it successfully
and verified in the
rotor winding
case
ent for reliable damage detection and there is no need for amplification of when
damage
machine is
the entire
powered from is showed the measured induced voltage obtained by measurin
the frequency converter. Voltage oscillation around zero enables in combination with a key phasor
the measured
sensor signal.
determination This
of the fault method,
position. besides
Each voltage for broken
oscillation rotor
represents barbar.
one rotor detection, motor and recorded by EMCM system. From the presented ex
can be usedsystem
The measuring for determination of the
connected to measuring coilsnumber of the complexity
can be of different broken bars, but
level. The also
simplest DMFM method is fully confirmed in practice and has a signifi
for determination
type, presented in Figureof11,
their mutuala comparator
is basically positions. From
which Figure
triggers 10 itrelay
an output canwhenbe voltage
seen
excides the pre-set value.
that the voltage of two measuring coils connected in series, for the rotor monitoring of rotating machines in various drives.
part without any winding damage, is not equal to zero. This occurs due
Figure 12. HG-WFD System (Hydro Generator Winding Fault Detection)
to allowed tolerances in the machine manufacturing and assembly and Figure 12. HG-WFD System (Hydro Generator Winding Fault Detection)
imperfections of measuring coils installation. However, one can clearly see
the change in the value of the measured voltage in the case of rotor broken The concept of the
TheEMCM
conceptsystem (Expertsystem
of the EMCM Machine Condition
(Expert MachineMonitoring) is presented in Figure
Condition Monitoring)
bar, which is almost 150% for the presented machine. TheThis method system has is specially
is presenteddesigned
in Figurefor13.
condition monitoring
This system of the
is specially induction
designed machines. The Figur
for condition
been tested for the entire operating range of the machine and shows the web monitoring
it succe- interface ofofthethe EMCM
inductionsystem.
machines. Through this 14
The Figure interface theweb
shows the end inter-
user can monito
ssfully detects rotor winding damage in the entire operating range. The
relevant parametersface ofofthethe induction
EMCM system.motor,
Through such as current,
this interface voltage,
the end bearing
user can monitorvibrations, sp
method has been tested and verified in the case when machine is powered and
temperatures, all relevant
especiallyparameters of the induction
the condition motor, such as
of the squirrel-cage current, The
winding. voltage,
condition of r
Figure 12.
from the frequency converter. Voltage oscillation around zeroHG-WFD System winding
(Hydro
enables (with
Generator
in orbearing Winding
withoutvibrations,
Fault Detection)
speed, temperatures,
fault) is monitored by application and of
especially
the DMFM the condition
method. On of the Figure
combination with a key phasor sensor determination of the fault position. the squirrel-cage winding. The condition of rotor winding (with or without
Each voltage oscillation represents one rotor bar.
is showed the measured induced voltage obtained by measuring coil embedded
fault) is monitored by application of the DMFM method. On the Figure 15 it
in the air gap of
The concept of the EMCM system (Expert motor Machine
and recorded
8 Condition Monitoring) is presented in Figure 13.
is showed the measured induced voltage obtained by measuring coil em- be seen that
by EMCM system. From the presented expert solutions, it can
The measuring system connected to measuring coils can be DMFMof different
method bedded
is fully in
confirmed inofpractice andandhasrecorded
a significant industrial application in condi
This system
complexity is specially
level. The simplest designed
type, presented for 11,
in Figure condition
is basicallymonitoring
monitoring aof rotating of thein
the air
machines
gap induction
the motor machines. The
by EMCM Figure
system.14 From
the presented expertvarious drives.
solutions, it can be seen that the DMFM method is
showswhich
comparator the triggers
web interface
an output relay of whenthe voltage
EMCM system.
excides the pre-Through this interface
fully confirmed in practice and thehas end user can
a significant monitor
industrial all in
application
set value.
relevant parameters of the induction motor, such condition as current,monitoring voltage,
of rotating bearing
machines invibrations,
various drives. speed,
temperatures, and especially the condition of the squirrel-cage winding. The condition of rotor
6winding part
(with
A. Elez, J. or without
Študir, fault) isofmonitored
S. Tvorić, Application by Field
Differential Magnetic application
Measurement of
(DMFMthemethod)
DMFM method.
in winding On ofthe
fault detection Figure
AC rotating 15 itas
machines
of expert monitoring systems, Journal of Energy, vol. 67 Number 3 (2018), Special Issue, p. 3–8
is showed the measured induced voltage obtained by measuring coil embedded in the air gap of the
motor and recorded by EMCM system. From the presented expert solutions, it can be seen that the
 WEB client EMCM

WEB client EMCM

ethernet HMI
Local client
ethernet HMI
Local client

magnetic
field
vibration current magnetic
vibration
temperature field
vibration current temperature
vibration
temperature
temperature

Figure 13. Concept of EMCM system

Figure 13. Concept of EMCM system
Figure 13. Concept of EMCM system

MOTOR CURRENT
MOTOR CURRENT

SECOND BEARING
SPEED SECOND BEARING
SPEED

FIRST BEARING
FIRST BEARING

ROTOR WINDING
ROTOR DAMAGE
WINDING DAMAGE

Figure 14. WEB interface of the EMCM system

Figure 14. WEB interface of the EMCM system
Figure 14. WEB interface of the EMCM system
10
10
A. Elez, J. Študir, S. Tvorić, Application of Differential Magnetic Field Measurement (DMFM method) in winding fault detection of AC rotating machines as
7 part of expert monitoring systems, Journal of Energy, vol. 67 Number 3 (2018), Special Issue, p. 3–8
 Figure 15. The induced voltage signal from measuring coil recorded by EMCM system
Figure 15. The induced voltage signal from measuring coil recorded by EMCM
system

A numerous FEM models have been developed to confirm this method.

CONCLUSION
CONCLUSION The method is tested for wide range of fault combinations but also for
different machine operating conditions. Method is confirmed by the exten-
This paper describes a new patent-pending method applicable for rotor sive laboratory tests on real models for various machine loads and for
This paper
winding inter-coildescribes a newofpatent-pending
short circuit detection synchronous machines method
and in- applicable for with
machines operating rotor andwinding inter-coil
without a frequency short
converter. circuit
Method has
duction machines with slip rings, as well as rupture of one or more rotor already implemented on more than 20 machines in the industry and is
detection
bars and cage of ringsynchronous machines
of induction machines. The DMFM and induction
method presented machines
tested and with
proven.slip
Fromrings, as results,
measuring well asonerupture of one
can conclude or
that this
more rotor bars and cage ring of induction machines. The DMFM method presented in this paper
in this paper enables reliable detection of these faults. The technical no- new DMFM method enables much simpler fault detection with significantly
velty of this new method is a differential measurement of the magnetic field higher sensitivities.
enables
inside reliable
the machine. detection
Measurement of these
is performed faults.
by two The technical
serial connected novelty of this new method is a differential
Furthermore, this new method and performed FEM calculations improves
measurement
measuring of
coils, installed the
on themagnetic field
stator tooth inside a inside
machine airthe
gap.machine. Measurement
fault detection is performed
portfolio knowledge
Measuring coils must be installed on two stator teeth which, by absolute diagnostics of rotating machines.
that can be usedbyin monitoring
two serial and
connected
value, have equal measuring
magnetic vectorcoils, installed on the stator tooth inside a machine air gap. Measuring coils must
potential.
be installed on two stator teeth which, by absolute value, have equal magnetic vector potential.
A numerous FEM models have been developed to confirm this method. The method is tested for wide
range of fault combinations but also for different machine operating conditions. Method is confirmed
by the extensive laboratory tests on real models for various machine loads and for machines operating
with and without a frequency converter. Method has already implemented on more than 20 machines
in the industry and is tested and proven. From measuring results, one can conclude that this new
DMFM method enables much
BIBLIOGRAPHY simpler fault detection with
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A. Elez, J. Študir, S. Tvorić, Application of Differential Magnetic Field Measurement (DMFM method) in winding fault detection of AC rotating machines as
8 part of expert monitoring systems, Journal of Energy, vol. 67 Number 3 (2018), Special Issue, p. 3–8