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Stator Winding Fault Detection in Induction Motor

Drives Using Signal Injection


G. R. Bossio, C. H. De Angelo, P. M. de la Barrera, J. A. Solsona, G. O. Garcı́a and M. I. Valla

Abstract—A stator winding turn fault diagnosis strategy in stator core. For such reason, an early detection of incipient
induction motor (IM) drives is proposed in the present work. winding faults is very important.
This strategy is based on the effects of the inductance variations A strategy for stator winding fault detection in variable-
coming from fault, over zero-sequence voltage. This voltage
is measured when a predefined inverter-switching pattern is speed induction motors (IM), with star connection, is presented
applied, allowing then decoupling the strategy from the motor in this paper. This strategy is based on the effects of such
fundamental excitation. For the evaluation of the feasibility of faults when the motor is fed by an additional excitation to
this proposal, a multiple-coupled circuit model of the IM is the fundamental one. The additional excitation consists on a
used. Experimental results are included to show the ability of predefined sequence of pulses applied by the inverter and it
the proposed strategy for detecting incipient faults, including a
low number of short-circuited turns. was previously used for position estimation [11] and for fault
diagnosis such as broken bars and rings [12] and air-gap eccen-
Index Terms—Induction motor, Fault Diagnosis, Signal Injec-
tricity [13]. The excitation signal injection allows decoupling
tion.
the diagnosis signal from the fundamental excitation aimed to
generate the motor torque. Variations on the IM inductance
I. I NTRODUCTION values, under fault conditions, produce significant changes on
TATOR winding turn faults are one of the most common the signals obtained from zero-sequence voltage, thus allowing
S faults in electric motors [1]. The gradual damage of the
winding insulation can occur due to overheat, transient over-
the incipient fault diagnosis.
The present work is organized as follows: an IM model
voltage, winding movements or contamination. The use of that allows considering the winding fault effects is presented.
variable-speed drives increases these problems due to the Then, the proposed diagnosis strategy is described, and the
high rates of voltage changes produced by inverter switching diagnosis signals are determined. After that, the effect of faults
[2]. All this motivated investigators to develop strategies for on diagnosis signals, using the IM model, is analyzed. Finally,
stator fault diagnosis, specially designed for variable speed experimental results that validate the proposal are given and
drives. Some techniques use artificial intelligence to detect the main conclusions drawn.
stator and other motor faults [3] from current and voltage
measurement, while other strategies, based on observers [4] II. I NDUCTION M OTOR M ODEL
or parameter estimation [5] have also been proposed. Other
The multiple-coupled circuit model proposed in [14] is
proposals take advantage of the inverter capabilities to inject
used for the IM analysis. Saturation and eddy-current effects
additional signals, in order to extract information about the
are neglected in this model. In addition, the rotor bars are
fault, both in induction motors [6]–[9] and other machines
supposed to be isolated. An m-circuit stator and n-bar rotor
[10].
IM is considered. The rotor cage is modeled as n-identical
Winding insulation damages may cause faults which in turn
and equally spaced loops, constituted by two consecutive bars,
produce high currents and winding overheating. This over-
plus a current loop on one of the rings. The inductances used
heating can quickly result in severe faults between windings
in this multiple-circuit model are deduced from the equations
of different phases or between winding and ground, producing
proposed in [15].
then permanent and irreversible damages both in windings and
This work was supported by Universidad Nacional de Rı́o Cuarto (UNRC), A. Stator fault modeling
Universidad Nacional del Sur (UNS), Universidad Nacional de La Plata
(UNLP), ANPCyT, CONICET and MINCyT-Cba. All the modifications on the multiple-circuit model, neces-
G. R. Bossio, C. H. De Angelo, P. M. de la Barrera and G. O. Garcı́a are
with CONICET, and also with the Grupo de Electrónica Aplicada (GEA),
sary to include stator winding turn faults, were carried out as
Facultad de Ingenierı́a, UNRC, Ruta Nacional #36 Km. 601, X5804BYA, in [16]. Fig. 1 shows a scheme of the stator windings, with a
Rı́o Cuarto, Argentina. (gbossio@ing.unrc.edu.ar, cdeangelo@ieee.org, pbar- turn-to-turn fault on the phase-a, where the shorted turns form
rera@ieee.org and g.garcia@ieee.org).
J. Solsona is with CONICET and also with Instituto de Investigaciones en
the f circuit.
Ingenierı́a Eléctrica “Alfredo Desages”, Departamento de Ingenierı́a Eléctrica The equations that describe the IM dynamics are,
y de Computadoras, UNS, Av. Alem 1253 (8000) Bahı́a Blanca, Argentina
(jsolsona@uns.edu.ar). dλs
M. I. Valla is with Laboratorio de Electrónica Industrial, Control e
Vs = Rs Is + (1)
dt
Instrumentación (LEICI), Departamento de Electrotecnia, Facultad de In-
genierı́a, UNLP, 1900 La Plata, Argentina, and also with CONICET dλr
(m.i.valla@ieee.org). 0 = Rr Ir + (2)
dt

978-1-4244-9303-6/11/$26.00 ©2011 IEEE

92
Mutual Inductance, LAR1 (mH)
0.1

ia if
0

−0.1
ib ic
0 1 2 3 4 5 6
Rotor Position, θr (rad)

Fig. 2. Mutual inductance between phase a and the rotor loop R1 , with five
shorted turns.
Fig. 1. Stator windings with a turn fault in the phase a.

15

Mutual Inductance, LFR1 (μH)


dλf
0 = Rf if + (3)
dt
where, Vs , Is , λs , Ir and λr are the voltage, current and
flux stator and rotor vectors, respectively. R s y Rr are the 0

stator and rotor resistance matrices, respectively. i f and λf


are the current and flux linked by the short-circuited turns,
respectively.
−15
The fluxes linked by the stator, rotor and the short-circuited 0 1 2 3 4 5 6
Rotor Position, θr (rad)
turns are given by,
λs = Lss Is + Lsr Ir + Lsf if (4) Fig. 3. Mutual inductance between the five shorted turns of a1 and the rotor
loop R1 .
λr = Lrs Is + Lrr Ir + Lrf if (5)
λf = Lf s Is + Lf r Ir + Lf f if (6) III. S TATOR FAULT D ETECTION S TRATEGY
where Lss is a 3 ∗ 3 matrix with self and mutual stator Considering a star-connected IM fed by a three-phase in-
inductances, Lrr is an (n + 1) ∗ (n + 1) matrix with self verter, motor asymmetries such as air-gap eccentricity, broken
and mutual rotor inductances, L sr is a 3 ∗ (n + 1) matrix with rotor bars or short-circuited turns affect the zero-sequence
the mutual inductances between the stator phase and the rotor voltage. Using an additional excitation to the fundamental one,
loops, Lrs is an (n+ 1)∗ 3 matrix with the mutual inductances it is possible to extract information about the asymmetries
between the rotor loops and the stator phases, L sf is a 3 ∗ 1 from the zero-sequence voltage. The additional excitation
vector with mutual inductances between the stator circuits and used in this paper for the stator winding faults detection
the shorted turns and L sf = LTfs . Lrf is an n ∗ 1 vector consists in a predefined inverter-switching pattern applied to
with mutual inductances between the rotor loops and shorted the motor for a short time while the fundamental excitation
turns as components and L rf = LTfr . Lf f is the shorted turns is canceled. This excitation was used previously to implement
self inductance composed by the magnetization inductance and a position estimation strategy [11]. Fig. 4 shows a scheme of
leakage inductance. the proposed strategy. The control loop of the fundamental
As an example, the mutual inductances between the dam- current i∗sf is canceled during the injection of exploratory
aged phase and one rotor loop as well as those between ∗
signal vse . Pulse Width Modulation (PWM) commands the
the same loop and the shorted turns for a fault in the first inverter to apply the additional excitation signal composed
winding of the phase-a are shown. Both, the characteristics by the inverter’s six active states applied in the following
and distribution of the windings are detailed in Table I. Fig. sequence u1 (+ − −), u4 (− + +), u3 (− + −), u6 (+ − +),
2 shows the mutual inductance between the phase a and the u5 (− − +) and u2 (+ + −) [11].
loop 1 of the rotor in thick line, and its derivative in thin line, The zero-sequence voltage is obtained from the sum of
for a five-turn fault in the a 1 winding. Fig. 3 shows the mutual voltages of the three phases respect to the motor neutral point,
inductance and its derivative, between the 5 shorted turns and vsn = [va vb vc ],
the loop 1 of the rotor. Results demonstrate that such fault
uσ = va + vb + vc (7)
reduces the mutual inductance between the damaged phase and
the rotor loops in the region where there are shorted turns. If measured synchronously respect to the injection of voltage
the mutual inductance between the shorted turns and one of pulses.
the rotor loops is added to that between the damaged phase By doing the difference between zero-sequence voltages for
and the same loop, then, the mutual inductance between the opposite switching states,
same phase with no fault and the corresponding rotor loop can
be obtained. pa = u(1) (4)
σ − uσ (8)

93
Fig. 4. General scheme of the diagnosis strategy.

 
pb = u(3) (6)
σ − uσ (9) Lsrf = LTrf s = Lsr Lsf (17)
pc = u(5) − u(2) (10)  
σ σ Lrr Lrf
(x) Lrf rf = (18)
where uσ is the zero-sequence voltage corresponding to the Lf r Lf f
inverter state ux , then, speed voltage effects can be almost
totally eliminated and the voltage signal results a function of From the model expressed by (14) and (15) and proceeding
the phase inductances where the excitation is applied. For an as in [17], then the diagnosis signals can be obtained as
IM with no faults, these three signals are almost sinusoidal and functions of the motor inductances,
 −1
their fundamentals present an n-period-per-revolution, where
M Lss − Lsrf L−1 rf rf L rf s NTa
n is the number of bars [17]. pa = −2 Ud  −1 (19)
By transforming the three-phase signals into an α and β M Lss − Lsrf L−1 L M T
rf rf rf s
coordinate system fixed to the stator, it is possible to define a
spatial vector P (θn ) = (pα , pβ ), which contains information  −1
about asymmetries or saliencies of the IM. M Lss − Lsrf L−1
rf rf Lrf s NTb
pb = −2 Ud  −1 (20)
M Lss − Lsrf L−1
rf rf Lrf s MT
IV. A NALYSIS OF FAULT E FFECTS ON THE D IAGNOSIS
S IGNALS  −1
M Lss − Lsrf L−1
rf rf Lrf s NTc
For the effects of winding faults on diagnosis signals to pc = −2 Ud  −1 (21)
be analyzed, the multiple-coupled circuit model with the
M Lss − Lsrf L−1
rf rf Lrf s MT
modifications proposed in Section II was used. If the time
of the exploratory signal injection is short, then, it is possible where,  
for the speed electromotive force effects and resistance voltage M= 1 1 1 (22)
drops to be neglected and consequently the equations for the  
motor with fault result in, Na = 2 −1 −1 (23)
dIs dIr dif  
Vs = Lss + Lsr + Lsf (11)
dt dt dt Nb = −1 2 −1 (24)
dIs dIr dif  
0 = Lrs + Lrr + Lrf (12)
dt dt dt Nc = −1 −1 2 (25)
dIs dIr dif
0 = Lf s + Lf r + Lf f (13) and Ud is the inverter DC voltage.
dt dt dt Fig. 5(a) shows signals p β vs. pα for a motor with no stator
Grouping conveniently, faults, calculated from previous equations and with the motor
dIs dIrf parameters presented in Table I. This figure also shows the
Vs = Lss + Lsrf (14) almost circular trajectory of the vector, due to the geometric
dt dt
dIs dIrf distribution of bars. Fig. 5(b) displays signals p β vs. pα for
0 = Lrf s + Lrf rf (15) five shorted turns in the first winding of phase a. Such fault
dt dt
produces a signal displacement on the α−β plane, represented
where,  T by a DC component of the diagnosis signals, whereas the
Irf = Ir If (16) component produced by the rotor bars does not modify its

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120 120

80 80
a1-18 a1-0
40 40
a1-10 a1-5 a1-4 a1-3 a1-2 a1-1

pβ(V)
p (V)

0 0
β

−40 −40
−80 −80 Fig. 8. Details of winding a1 , in which faults can be generated.
−120 −120
−120−80 −40 0 40 80 120 −120−80 −40 0 40 80 120
p (V) p (V)
α α Winding a1 Induction
Motor
(a) (b) Induction
Motor
Fig. 5. Signals pβ vs. pα , (a) with no faults (b) five shorted turns. Drive
Phase c

−20 Phase b

−40 Phase a
pα0(V)

−60

−80 Fig. 9. IM with modified stator windings.


−100

0 1 2 3 4 5 6 7 8 9 10
Number of shorted turns Fig. 11(a) shows signals p β vs. pα for a motor with no
winding faults. Fig. 11(b) shows the effects of the five shorted
Fig. 6. Component pα0 as a function of the number of shorted turns. turns on the diagnosis signals. It can be observed from Fig. 11
that the turn fault of one phase produces a signal displacement
on α − β plane, in the opposite direction to the faulted phase.
amplitude. A similar result was presented by [7], where the Spectrum of the p α signal for the healthy motor is shown
effect on negative-sequence currents is analyzed when a bal- in Fig. 12(a), where only the component of 40 cycles/rev
anced, three-phase, high-frequency, voltage is injected to the produced by the 40 rotor bars is appreciated. However, for
motor in order to obtain diagnosis signals. The displacement the motor with five shorted turns, a DC component appears in
direction on the α − β plane indicates the location of the the spectrum (Fig. 12(b)), which produces the displacement of
affected winding. The amplitude of the displacement on the the signal in the α − β plane. The DC component produced
α − β plane as a function of the number of shorted turns is by the fault is obtained by first canceling the offset produced
shown in Fig. 6. It can be observed that for a low number of by other saliencies and that due to voltage sensors and A/D
shorted turns, the amplitude of the DC component increases converter. The magnitude of the DC component produced by
its value significantly, tending to a constant value for a higher fault, as a function of the number of shorted turns, is given in
number. Fig. 13. These results, similar to those obtained through the
model-based analysis, show that it is possible to detect a small
V. E XPERIMENTAL R ESULTS number shorted turns.
A discontinuity in the DC component’s amplitude, p α0 ,
To validate the diagnosis strategy performance, the windings corresponding to a change from five to six shorted turns,
of a motor were modified so as to make it possible shorting can be observed in Fig. 13. Asymmetries that justify such
different number of turns of the windings of the phase a. Fig. 7 discontinuity on the shorted turns were not observed. However,
displays a scheme of the complete stator winding, while Fig. 8 there exists a difference in the windings’ connections to
shows a detail of the modified phase a 1 winding. Fig. 9 shows achieve a desirable number of shorted turns. For the first five
the test bench and the IM with modified stator windings. shorted turns, the end of phase a, a 1−0 , was connected to
Fig. 10 shows a block diagram of the laboratory prototype. the outputs a1−1 , a1−2 , a1−3 , a1−4 and a1−5 , producing the
The diagnosis strategy was implemented on a PC, in which short circuit at the beginning of the phase. For the following
both the fundamental current control and the exploratory signal windings, 6 to 10, the output a 1−10 was connected to the
references are generated. outputs a1−4 , a1−3 , a1−2 , a1−1 and a1−0 respectively. For the
Experimental results were obtained with the motor at 30 first four cases, there are not shorted turns at the beginning of
r/min, with no fundamental excitation, and driven by a stan- the phase.
dard drive. Due to the fact that the average voltage, injected
by the exploratory signal, is equal to zero, and that each
VI. C ONCLUSIONS
exploratory signal state only lasts 75 μseg, it would not be
necessary to limit the currents on the faulted turns through an A strategy for stator winding fault detection in IM was
external resistance. proposed in this work. The proposal is based on a signal-

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Fig. 7. Modified stator winding.

100 100

80 80

60 60

p (V)

p (V)
α

α
40 40

20 20

0 0
0 20 40 60 80 100 0 20 40 60 80 100
Cycle/rev. Cycle/rev.

(a) (b)

Fig. 12. Spectrum of pα signal, (a) with no faults (b) five shorted turns.

0
Fig. 10. Block diagram of the laboratory prototype.
−20

−40
pα0(V)

120 120
−60
80 80
40 40 −80
p (V)
p (V)

0 0 −100
β
β

−40 −40 0 1 2 3 4 5 6 7 8 9 10
−80 −80 Number of shorted turns

−120 −120
−120−80 −40 0 40 80 120
Fig. 13. Component pα0 as a function of the number of shorted turns.
−120−80 −40 0 40 80 120
pα(V) p (V)
α

(a) (b)
R EFERENCES
Fig. 11. Signals pβ vs. pα , (a) with no faults (b) five shorted turns.
[1] S. Grubic, J. Aller, B. Lu, and T. Habetler, “A survey on testing
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those produced by winding faults [18]. In a future work, we [6] F. Briz, M. Degner, P. Garcia, and A. Diez, “High-Frequency Carrier-
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TABLE I
IM RATED DATA AND PARAMETERS . Symposium on Diagnostics for Electric Machines, Power Electronics
and Drives, 2011. SDEMPED 2011.
Variable Value
Pn (kW/HP) 5.5/7.5
Vn (V) 220/380
Guillermo R. Bossio (S’03 - M’07) received the Electrical Engineer degree
In (A) 19.9/11.1
from the Universidad Nacional de Rı́o Cuarto, Argentina, in 1999, and the Dr.
f (Hz) 50 of Engineering degree from the Universidad Nacional de La Plata, Argentina,
Tn (Nm) 35.00 in 2004. Since 1994, he has been with the Grupo de Electrónica Aplicada,
Facultad de Ingenierı́a, Universidad Nacional de Rı́o Cuarto. He is also
cosφ 0.82
currently with Consejo Nacional de Investigaciones Cientı́ficas y Técnicas
Efficiency η (%) 86 (CONICET), Argentina. His research interests include fault diagnosis on
electric machines, ac motor drives, electric vehicles, and renewable-energy
Pair of poles 2
generation.
Number of stator slots 48
Number of rotor bars n 40
Air-gap (mm) 0.45
Stator length (m) 0.11 Cristian H. De Angelo (S’96 M’05 - SM’10) received the Electrical Engineer
Air-gap radius (m) 0.075 degree from the Universidad Nacional de Rı́o Cuarto, Rı́o Cuarto, Argentina,
in 1999 and the Dr. of Engineering degree from the Universidad Nacional de
Rotor slot opening (mm) 2.5
La Plata, La Plata,Argentina, in 2004. Since 1994, he has been with the Grupo
Skewing One stator slot period de Electrónica Aplicada, Facultad de Ingenierı́a, Universidad Nacional de Rı́o
Stator winding 34 turns per coil, Cuarto. He is also currently with CONICET, Argentina. His research interests
include fault diagnosis on electric machines, sensorless motor control, electric
2 coil per group,
vehicles, and renewable-energy generation.
4 groups per phase,
in series connection,
step 1:10:12
Pablo de la Barrera (S’99 - GS’08 - M’09) received the Electrical Engineer
and the M.Sc. degrees from Universidad Nacional de Rı́o Cuarto, Argentina,
Fed AC Machines,” IEEE Trans. Ind. Electron., vol. 55, no. 12, pp. in 2003 and 2006, respectively and the Dr. of Engineering degree from the
4181–4190, 2008. Universidad Nacional del Sur, Argentina, in 2009. In 1998, he joined the
[7] F. Briz, M. Degner, A. Diez, and J. Guerrero, “Online diagnostics in Grupo de Electrónica Aplicada, Universidad Nacional de Rı́o Cuarto. He
inverter-fed induction machines using high-frequency signal injection,” is also currently with CONICET. His research interests are in modeling
IEEE Trans. Ind. Applicat., vol. 40, no. 4, pp. 1153–1161, 2004. and control of induction motor, in fault detection in electric machines and
[8] T. Wolbank, K. Loparo, and R. Wohrnschimmel, “Inverter statistics for renewable energy conversion
online detection of stator asymmetries in inverter-fed induction motors,”
IEEE Trans. Ind. Applicat., vol. 39, no. 4, pp. 1102–1108, 2003.
[9] R. Wieser, C. Kral, F. Pirker, and M. Schagginger, “On-line rotor cage
monitoring of inverter-fed induction machines by means of an improved
method,” IEEE Trans. Power Electron., vol. 14, no. 5, pp. 858–865, Guillermo O. Garcı́a (M’86 - S’90 - M’95 - SM’01) received the Elec-
2002. trical and Electronics Engineering degree from the Universidad Nacional de
[10] J. Arellano-Padilla, M. Sumner, and C. Gerada, “Winding condi- Córdoba, Argentina, in 1981, and the M.Sc. and Dr. degrees in electrical
tion monitoring schemefor a permanent magnet machine using high- engineering from COPPE, Universidade Federal do Rio de Janeiro, Brazil,
frequency injection,” IET Electric Power Applications, vol. 5, no. 1, pp. in 1990 and 1994, respectively. In 1994, he joined the Universidad Nacional
89 –99, 2011. de Rı́o Cuarto, Argentina, where he is currently Director of the Grupo de
[11] J. Jiang and J. Holtz, “Accurate estimation of rotor position and speed of Electrnica Aplicada. He is also with CONICET. His research interests are in
induction motors near standstill,” in International Conference on Power power electronics, electric vehicles and renewable energy conversion.
Electronics and Drive Systems, vol. 1, 1997, pp. 1–5.
[12] G. Bossio, C. De Angelo, G. Garcia, J. Solsona, and M. Valla, “Effects
of rotor bar and end-ring faults over the signals of a position estimation
strategy for induction motors,” IEEE Trans. Ind. Applicat., vol. 41, no. 4,
pp. 1005–1012, 2005. Jorge A. Solsona (S’94 - M’96 - SM’04) received the Electronics Engineer
[13] G. Bossio, C. De Angelo, J. Solsona, G. Garcia, and M. Valla, “Ap- and Doctor in Engineering degrees from the Universidad Nacional de La Plata,
plication of an additional excitation in inverter-fed induction motors for La Plata, Argentina, in 1986 and 1995, respectively. Currently, he is with the
air-gap eccentricity diagnosis,” IEEE Trans. Energy Conversion, vol. 21, Instituto de Investigaciones en Ingenierı́a Eléctrica “Alfredo Desages” (IIIE),
no. 4, pp. 839–847, 2006. Departamento de Ingenierı́a Eléctrica y Computadoras, Universidad Nacional
[14] X. Luo, Y. Liao, and H. Toliyat, “Multiple coupled circuit modeling del Sur and the CONICET. He is involved in teaching and research in control
of induction machines,” IEEE Trans. Ind. Applicat., vol. 31, no. 2, pp. theory and its applications to electromechanical systems.
311–318, 1995.
[15] G. Bossio, C. De Angelo, J. Solsona, G. Garcia, and M. Valla, “A 2-D
model of the induction machine: an extension of the modified winding
function approach,” IEEE Trans. Energy Conversion, vol. 19, no. 1, pp.
144–150, 2004. Maria I. Valla (S’79 M’80 SM’97 - F’10) received the Electronics Engineer
[16] G. Joksimovic and J. Penman, “The detection of inter-turn short circuits and Doctor in Engineering degrees from National University of La Plata
in the stator windings of operating motors,” IEEE Trans. Ind. Electron., (UNLP), La Plata, Argentina, in 1980 and 1994, respectively. She is currently
vol. 47, no. 5, pp. 1078–1084, 2002. a Full Professor with the Laboratorio de Electrónica Industrial, Control
[17] G. Bossio, C. De Angelo, G. Garcia, J. Solsona, and M. Valla, “Analysis e Instrumentación, Departamento de Electrotecnia, Facultad de Ingenierı́a,
of a position estimation strategy using a multiple-coupled circuits model UNLP. She is currently also with the CONICET, Argentina. She is engaged
of the induction motor,” in 28th Annual Conference of the Industrial in teaching and research in the areas of power converters and ac motor drives.
Electronics Society (IEEE IECON 02), vol. 1, 2002, pp. 822–827. Prof. Valla is a member of the Buenos Aires Academy of Engineering in
[18] P. M. de la Barrera and G. R. Bossio, “Stator core fault detection on Argentina. She is the VP for Membership of the IEEE Industrial Electronics
induction motor drives using signal injection,” in IEEE International Society.

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