Review of Induction Motor Testing and Monitoring

Methods for Inter-turn Stator Winding Faults

M. Eftekhari, Graduate student Member, IEEE , M. Moallem, Senior Member, IEEE, S. Sadri, Member, IEEE, A.
Shojaei, Graduate student Member, IEEE
Department of Electrical and Computer Engineering,
Isfahan University of Technology,
Isfahan, Iran
m.eftekhari@ec.iut.ac.ir

Abstract—This paper provides a literature review on inter-turn mechanisms of fault propagation are reviewed. Section III,
short-circuit faults in stator windings of induction motors. As includes a comprehensive overview on condition monitoring
evidenced by credible surveys stator winding breakdown is a of inter-turn fault in stator windings of induction motors.
large group of induction motor failures which undetected inter- Finally, some concluding remarks end this review paper.
turn fault is considered as the root cause for this category of the
fault. Although monitoring approach are divided into different II. STATOR WINDING INTER-TURN FAULT
categories, we focused on continuous on-line methods due to the Although deterioration process of the stator winding
installation of induction motors in many continues processes. insulation is caused by a combination of various stresses
acting on the stator; usually inter-turn fault incepts an
I. INTRODUCTION insulation failure between two windings in the stator winding
Three-phase Induction Motors (IM) are the workhorse of phase.
industry; however, they are subjected to some undesirable
stresses, causing some faults resulting in failure [1]. As shown in Fig. 1, in an inter-turn fault number of turns
in a stator coil is short-circuited. The current in the shorted
Condition Monitoring (CM) and system diagnosis as the turns, in order of twice locked-rotor current, causes severe
predictive maintenance techniques has received considerable localized hot-spot. By occurring inter-turn fault, it propagates
impetus from industry for monitoring the operating to larger section of the windings which founding a coil-to-coil
characteristics of electrical and mechanical systems within the short circuit or a phase-to-phase short circuit [4]. These faults
industrial processes. CM can greatly improve reliability, again can develop into phase-to-ground faults, which can
availability, operational efficiency and reduce consequential cause significant damage to the motor. Failure of insulation
damages, break-down losses, and operating costs leading to a between winding and ground can cause a large ground current,
spurt in research activity in industry and academia. resulting in irreversible damage to the core of the machine [5].
Several surveys are conducted on reliability of induction The Stator winding turn fault produces one or more of the
motors under the auspices of the IEEE-IAS, EPRI, and symptoms as follows [3]:
Allianz. These studies have shown that there are four types of
motor faults which are considered as the most prevalent,
namely, stator faults, bearings faults, broken rotor bars/end
rings, and air-gap eccentricity [2]. As shown in these surveys,
30%–40% of induction motor failures are due to stator
winding breakdown. These faults are usually related to
insulation failure while winding insulation failures usually
begin as an undetected inter-turn fault [3]. Therefore,
detecting inter-turn fault can be beneficial in preventing stator
winding insulation failure.
This paper aims at providing a survey of available
techniques for monitoring and detecting of stator winding
inter-turn fault. In section II, stator winding inter-turn fault
definition, the root causes of the fault sprouting, and
Figure 1. Schematic representation of stator possible failure modes.
 1) Unbalanced air-gap voltages and line currents;
2) Increased torque pulsations;
3) Decreased average torque;
4) Noise and vibration;
5) Increased losses and reduction in efficiency;
6) Excessive heating [4].
Although there is no experimental data to indicate the time
delay between inter-turn and ground-wall insulation failure, it
is probable that the transition between the two states is not
instantaneous. Hence, detecting inter-turn fault at an incipient
stage would eliminate following damages, decreasing
maintenance cost and motor break-down time span [6].
Therefore, for the purpose of detecting such fault related
signals, many diagnostic methods have been developed so far.
Hence, presenting a review describing various diagnostics
schemes will not be entirely out of place.
III. TESTING AND MONITORING METHODS
The testing and monitoring methods can be commonly
divided into off-line and on-line testing. In off-line testing, the
inspected motor needed to be removed from service, while in
on-line monitoring the motor is on operation.
Moreover, the CM can be divided into two different
categories, periodical and continuous testing. The periodical
condition monitoring methods are designed off-line or on-line
monitoring but the continuous monitoring is usually made on-
line [7].
In continuous on-line CM the machine doesn't have to be
taken out of service. In addition, predicting health condition
and detecting faults at an incipient stage is made easier.
However, in continuous on-line CM installation of extra
sensors is usually required which cost more investment
compared to periodical on-line CM.
For continues online condition monitoring methods,
sensorless methods which are using only currents and voltages
of the motor are preferred due to their low cost and non-
intrusiveness. Also, most drive systems are equipped with
current sensors to provide good controllability; hence using
stator currents for fault detection can minimize the number of
additional sensors required in incipient fault detection [8].
Due to the installation of induction motors in many
continuous processes, in this survey, we focus mostly on
continues online condition monitoring methods. In this paper,
methods are categorized in six main groups. Also, artificial
intelligent systems are surveyed to overcome the interpretation
of complex relation between fault signatures and motor
condition.
A. Axial Leakage Flux
Axial leakage flux is presented, by existing asymmetries in
the motor. Since asymmetries can be created by inter-turn
fault, the monitoring of frequency components of this flux can
be used for detecting inter-turn faults. Penman et al. [9] were
able to detect inter-turn faults by analyzing the axial flux
component of machine using a large coil wound concentrically
around the shaft of the machine. Even the fault position could
be detected by mounting four coils symmetrically in four
quadrants of the motor at a radius of about half the distance
from the shaft to the stator end winding. Although, this
technique works properly in case of presenting supply
harmonics, it can’t be used extensively in industry because of
installing search coils. Also, this technique strongly depends
on the motor load torque which makes setting alarm levels
difficult.
B. Motor Current Signature Analysis
Motor Current Signature Analysis (MCSA) is briefly
presented in the following. In these techniques, just current
and voltage sensors are needed which is mostly available in
motor drive systems. Hence, these techniques are so common
due to their low cost and non-intrusiveness. The accuracy of
these techniques depends on the loading of the machine, and
also the signal to noise ratio of the measuring instruments
[10].
1) Stator Current Spectrum Analysis
By developing inter-turn fault in stator windings of IM, the
magnitude of the stator current harmonics changes. In [6], the
third harmonic and rotor slot harmonic frequencies are
observed. However, saturation of magnetic material, and also
unbalanced supply voltage produce the third harmonic
component in the line current spectra of a healthy machine.
Further, rotor slot harmonic components can rise due to
static eccentricity condition which makes interpretation of the
harmonic components difficult.
Nevertheless, third harmonic in the motor supply currents
of Direct Torque Control (DTC) induction motor drive leads
to inter-turn short-circuits fault detection [11].
Although stator current spectrum may be confused with
voltage unbalance in some machines, Nandi and Toliyat [3]
detected stator currents at the terminal voltages of the machine
just after switching it off by considering the shorted stator
turns as a search coil to pick up rotor magnetomotive-force
(mmf) harmonics. Although, this method is immune to supply
voltage unbalance, it cannot provide continuous monitoring.
2) Stator Power Analysis
Spectral component and AC-component of power signals
in all three phases are proposed to give information about the
motor condition. The AC-component of the power signal can
detect inter-turn fault for severity of over 5% short circuit in
stator winding [12, 13].
3) Three-phase Shifts
The values of the three-phase shifts between the line’s
current and the phase voltage are used as inter-turn short-
circuit fault indicator in the stator windings of the IM [14].
The diagnostic process is automated through monitoring
simultaneously these parameters by a simple neural network.
Also, there isn’t significant change of the value of phase
voltage and line's current due to the supply unbalance.
4) Park's Vector Approach
Park's vector approach is a two-dimensional representation
describing three-phase IM phenomena based on the stator
current Park’s vector [15]. The corresponding representation is
a circular locus centered at the origin of the coordinates in
healthy condition which varies to an elliptical pattern in faulty
case. Degree of ellipticity and major axes orientation of the
pattern determine the fault severity and the faulty phase.
Extended Park’s Vector Approach (EPVA) introduced the
information contained in the modulus of the current Park’s
vector [10]. In this technique, the presence of the fault and its
severity will be appeared by the presence of a spectral
component at twice fundamental supply frequency and the
ratio between the amplitude of the spectral component at 2 f s
and the DC level of the current Park’s Vector.
Applying park transformation mass center to the stator
currents make a single point in a healthy IM. However, it
obtains specific pattern in a motor subjected to inter-turn fault
in the d-q plane. The circumference radius and mass center are
selected as extracted features of the pattern for identifying
stator winding fault which depends on fault severity.
However, this method can’t specify the faulty phase. Since
this method is insistent in supply voltage unbalances, it can
also be used in case of PWM feed induction motors [16].
As the previous methodologies can’t work properly in
transient condition, therefore Douglas et al. [17] proposed
examining detail coefficients of the non-stationary EPVA
magnitude signal using Daubechies wavelet which can
measure the fault severity.
5) Space Vector Angular Fluctuation (SVAF)
The position of the current space vector in the space vector
plane is explored in this method. Fourier transformation of the
phase angel variations and the SVAF spectrum are analyzed in
[18] which taken as diagnostic indexes for inter-turn fault.
Since this method is not immune to the supply voltage
unbalances, it is combined with voltage space vector angular
fluctuation to avoid unreliable results.
C. Sequence Component
1) Current/ Voltage Sequence
Negative sequence current component of the motor’s
phase currents introduced as the first indicator for inter-turn
fault diagnosing. Toliyat and Lipo showed variation of this
parameter in existence of stator winding asymmetries;
however, this parameter strongly depends on other
asymmetries like unbalance voltage supply, machine
saturation and etc [21].
In [20], Kilman et al. modeled those unbalances that even
can detect one shorted turn, out of 648 turns per phase.
The difference between the positive-sequence of current
under the faulty and healthy condition divided by the positive
sequence current under the healthy conditions is also
introduced as an inter-turn fault detecting index [23].
In [22] variations of voltage negative and positive
sequence components are investigated. Results show
sensitivity of positive and negative sequence voltage to the
stator winding deterioration; however negative sequence
voltage appears more sensitive to the amount of fault severity,
absolute changes in the positive sequence voltage are larger.
Also, due to stator current regulating in closed loop drives,
voltage negative sequence can be used as the fault signature
instead of current negative sequences.
2) Sequence Impedance Matrix
Since, negative sequence current depends on unbalance
voltage supply, apparent negative-sequence impedance is
introduced as an inter-turn fault indicator in [24].
The off-diagonal terms of the sequence component
impedance matrix are also used as inter-turn fault detecting
signatures which are insistent to supply voltage unbalances.
Variation of Znp which represents the impedance of the
negative sequence due to the positive sequence is used in [8]
with strong immunity to inherent asymmetries.
3) Injection of High Frequency Signal
Appearing the negative sequence component due to
injecting low-magnitude high frequency (HF) voltage,
superimposed to the fundamental excitation in inverter fed
machines was examined in [25]. Since the negative sequence
component doesn’t depend on the frequency of the injected
signal, high frequency signal is selected for injection to
minimize the influence on the machine's operation.
4) Zero Sequence Voltage
Utilizing the zero sequence voltage is proposed in [26].
Ideally this sum should be zero. Although, this parameter is
not sensitive to supply or load unbalances, it reflects load
variation. Also, the neutral of the machine is needed in this
method which is not accessible in many cases.
D. Vibration Monitoring
Electrically excited vibration will be caused due to the
total air gap magnetic field in induction motors. In [19], the
current and vibration signals spectrum relationship is
determined using the coherence analysis. Special frequency
values represented in this method are used for interpreting the
characteristics of the insulation and stator current imbalances.
E. Air-gap Torque
The air-gap torque, produced by the flux linkage and the
currents of a rotating machine, is sensitive to unbalances
created by any kind of distortion like unbalance supply
voltages, cracked rotor bars or asymmetric stator windings.
Authors in [27] studied air-gap torque frequency components
in detecting inter-turn short-circuit fault. According to this
paper, the non-zero angular frequency of the torque shows the
faulty situation of the induction motor.
F. Temperature Monitoring
As mentioned in section II, inter-turn fault produces
excessive heating which can harm the insulation. As a rule of
thumb, there is a 50% loss of insulation life for each 10◦C
increase in the temperature [4]. Therefore, stator thermal
inspection is necessary in extending motor life and can be
used as an inter-turn fault detection technique.
1) Measuring Local Point Temperature Using Embedded
Detectors
Metallic sensors in this method are placed to measure the
local temperatures. Although using the embedded sensors is a
simple and cost effective method, the local hotspots can be
missed in this method. Also, due to installation of the sensors
in to the stator insulation, the measured temperature will be a
proportion of the copper temperature [28]. Optical fibers are
new devices in measuring high-voltage winding temperature
to avoid electrical short circuits by given electrical isolation
[1].
2) Thermal Devices
Fuses, thermal-magnetic circuit breakers, and overload
relays are widely used devices for thermal protection. Since
these devices can not follow the thermal characteristics of the
motor accurately, nuisance tripping and under-protection are
common when these devices are used [4].
3) Thermal Model-Based Approaches
Thermal model-based approaches are temperature
estimation techniques based on solving different orders of
analytical lumped circuit composed of heat resistances, heat
capacitances and power losses [4].
The first order thermal model just considers stator
windings temperature. Although solving this circuit is easy,
specifying thermal parameters are generally too difficult; and
they cannot adapt to change of cooling conditions. However,
this is a nonintrusive technique which doesn’t require
temperature sensors installation [33].
Higher order thermal models are also available to estimate
motor temperature in more detail inside the motor and also on
the motor housing. These models increase the temperature
estimation accuracy; however specifying the parameters is not
an easy task [33].
4) Parameter-based Approaches
In this approach stator winding temperature is estimated
according to the variation of the stator resistance which is not
affected by the running condition and the cooling mode.
The stator resistance can be determined by induction motor
modeling, neural network and or signal injection based
methods.
IM equivalent circuit is used for calculating stator resistant
in induction motor modeling approach. This method responds
well to changes in the cooling conditions. However, other
parameters like frequency and saturation are also effective in
stator resistance not being considered in this method [33].
Artificial neural networks are also used to estimate stator
resistance. Since these methods do not require the motor
parameters, it can be easily implemented by low cost hardware
[34].
In signal injection-based temperature estimation method,
the DC bias can be created in the stator supply voltage by an
extra injection circuit connected in series with one phase of
the machine or from the soft starter or the drive [35]. In this
method stator resistances are assumed equal in three phases
and thus it can't determine the specific faulty phase. In this
method accuracy of calculating stator resistance increases by
increasing magnitude of injected signal while smaller DC
signal is preferred to prevent torque distortion.
5) Finite Element Analysis Methods
Finite element method is used to analyze the thermal
behavior of the inspected motor according to specified losses
and heat transfer properties.
This method is based on solving coupled non-linear
differential equations that is time consuming and cannot be
used in continuous on-line monitoring.
6) Thermal Images
Thermal images are used in order to collect hot spots and
bulk information. Gathered data are processed to interpret the
machine condition. Manana et al. [34] described a simplified
thermal model besides thermal images for diagnosis of open
winding or an inter-turn fault in DC motors, during
manufacturing. In [35], thermal images are used for diagnosis
of stator core fault in induction motors by detecting hot spot.
Younus and Yang [36], used thermal images for diagnosis of
different fault condition such as misalignment, mass-
unbalance and bearing-fault. In that study, to analysis thermal
images, discrete wavelet decomposition is used to find out
significant result for machine condition monitoring.
Cooling system operation is also inspected by thermal
images, measuring the temperature of the cooling fluid, and
using optical fibers [28, 32].
Figure (2) shows infrared thermal images of a 2hP IM
under healthy, 26%, and 40% of one stator phase inter-turn
short circuit fault after 20 minutes working at 3 N.m load
torque. Pseudo-coloring is used to display hot spots clearly. In
these figures the part which is colored in magenta on the
motor body illustrates hot area. Obviously, hot area increases
by increasing the severity of the fault. Therefore, extracted
features from image processing techniques can possibly used
in detecting inter-turn fault and determining it’s severity.
As anticipated, there is a broader field of research for
infrared thermal imaging in this area; hence a short
comparison with other methods looks necessary at this step.
(a)
(b) (c)
Figure 2. Infrared thermal image of an induction motor under (a) healthy
motor, (b) 26% short circuit in stator winding on phase ‘a’, (c) 40% short
circuit in stator winding on phase ‘a’.
 1- Most of the listed approaches can be applied to low
voltage and medium voltage induction motors, while infrared
thermal imaging is suitable for low to high voltage induction
motors. However, a precondition to study any defects with
infrared thermal imaging is to operate the motor at minimum
30-40 % of the rated load.
2- Infrared thermal imaging can show hot-spots and bulk
information simultaneously which can lead to addressing the
root causes.
3- It seems that infrared thermal imaging can work for
both main-fed and inverter drive-fed (open loop/ closed loop)
motors similarly while it isn’t true for most of the other
methods.
4- As infrared thermal imaging show temperature outcome
on the motor case, presumably this method isn’t very sensitive
to the power supply transitions due to higher thermal time
constant compared to electrical time constant.
5- By using infrared thermal imaging, finding the faulty
motor in the condition of parallel motor drive system is likely
more simple than using other methods.
6- It seems that by using infrared thermal imaging, the
fault severity will be specified with image processing
techniques.
7- Using infrared thermal imaging, the inspection can be
conducted efficiently by keeping a distance from the inspected
equipment and prevent hazardous operation [48].
G. Artificial Intelligence in Induction Motor Monitoring
Due to the complex relation between the machine variables
and the fault phenomena and also the occurrence of multiple
faults simultaneously, human analysis is needed to interpret
the collected data in relation with the occurred fault.
Artificial Intelligent (AI) techniques, such as expert
systems, neural network, fuzzy, genetic algorithm etc are other
alternatives for this problem [36].
Authors in [37] used neuro-fuzzy system for detecting
existence and severity of inter-turn fault with motor currents
and voltages as inputs. Also in [38], fuzzy decision making
system was proposed using Park vector extracted patterns to
identify stator winding turn faults.
In [22] negative-sequence equivalent circuit is used for
detecting IM stator winding fault.
AI systems are advantageous compared to traditional
diagnosis techniques due to no need to detailed model of the
faulty system and just requiring a priori knowledge for
implanting the diagnosis tool.
Furthermore, AI systems are helpful in improving the
automation of the diagnostic process [5].
IV. CONCLUSION
In this paper, the existing continuous on-line monitoring
methods for the stator winding inter-turn fault diagnosis of
induction motors is reviewed. Capability and restrictions of
those methods are mentioned.
Therefore, it seems that one single method cannot
diagnose the stator inter-turn fault in all working conditions
accurately and combination of methods should be used.
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