DoctorKnow Application Paper

Title: Embedded Sensor Technology Migration Into A.C. Induction Motors Source/Author: Matthew M. O'kane Product: General, Motor Technology: Motor Classification:

Embedded Sensor Technology Migration Into A.C. Induction Motors

Matthew M. O'Kane U.S. ELECTRICAL MOTORS, DIVISION OF EMERSON ELECTRIC, ST. LOUIS, MISSOURI
ABSTRACT This paper presents the technological advancements of embedded sensors and microprocessors into A.C. induction motors and their ability to predict failure. Today, maintenance departments utilize several stand-alone technologies to detect and predict motor failure such as vibration and flux analysis. Intelligent motors now integrate multiple technologies that enable on-line monitoring of critical motor components as well as operating conditions. In today's global economy, the need to decrease operating expenses and to increase profitability sets the stage for the emergence of embedded sensor technology. INTRODUCTION The new global economic realities of consolidation and downsizing has significantly increased the awareness and the impact of continuous machine operation to profitability. The theory of Reliability-Based-Maintenance (RBM) will be provided to describe the overall goals and advantages to such an approach. This will then set-up the importance and feasibility to embedded sensors and microprocessors within A.C. induction motors and their potential corresponding economic impacts. PART I - ROOT MEAN CAUSE OF AC INDUCTION MOTOR FAILURE Since the invention of the first A.C. induction motor, the reality of eventual failure has never changed. What has changed however is the understanding of why motors fail and efforts to improve overall performance and life expectancy of the A.C. induction motor. The forces that impact the dynamic performance of any A.C. induction motor are many. Table 1 summarizes the key components of the induction motor and the stresses that contribute to failure.

Types of Stress Stator Winding Rotor Assembly Bearings Shaft Thermal X X X X Electrical/Dielectric x X x Mechanical X X X X Dynamic X X x Shear X Vibration/shock X X X X Residual X X ElectroMagnetic X X X X Environmental X X X X Table 1

PART II - THEORY OF RELIABILITY BASED MAINTENANCE (RBM) To discuss Reliability Based Maintenance, a definition is provided. RBM is a strategy to improve overall plant productivity by integrating Preventative Maintenance (PM), which is time or interval based; Predictive Maintenance (PDM) which is machinery conditioned based; and Proactive Maintenance (PAM) which is root-cause/failure analysis based, in a formal and balanced approach to modify the normal failure profile of A.C. induction motors along with all other plant machinery. Predictive Maintenance is the key to this balance, along with possessing the appropriate tools to monitor the condition of driven machinery. The results of this monitoring provides the necessary information required to take pro-active steps once potential failure is identified. Figure 1 illustrates the typical profile of plant machinery through the use of RBM.

Figure 1

The goals of implementing a comprehensive RBM strategy are numerous and are summarized as: Increased plant capacity and throughput through the elimination of downtime. Reliable knowledge of machinery condition providing status of overall plant capacity. Extension of the useful service life of plant machinery through identification and elimination of failure modes at the source. Development of work teams responsible for the combination of maintenance and capacity. Maintenance, production, and engineering working and communicating as partners to maximize plant capacity. Maintenance providing credible machine information which will assist in crucial decision-making on plant operations. Environment that supports a learning organization where mistakes are not repeated. Development of a systematic approach for each maintenance situation (reactive, preventive, and predictive) based on logic and history. Senior management buy-in along with an increase participation in all levels of management in the support of RBM strategies. PART III - RBM TECHNOLOGIES

Multiple technologies exist today that are utilized in the area of predictive and preventative maintenance. The most widely implemented technology today is vibration analysis. However, with the advancement in microprocessor technology, the result has lead to smaller and less expensive portable equipment. Several companies provide industry with an array of portable equipment capable of monitoring the following: Vibration analysis Oil and wear particle analysis Infrared thermography Precision alignment and balancing

 Motor stator flux Motor current signature analysis Ultrasonics The implementation of these multiple technologies provides for the user to identify potential problems with the A.C. induction motor along with other rotating equipment. A shortcoming of several key technologies such as vibration is that they will view data for the short instant in time while they are connected to the motor. The result of this approach is that it does not provide for any operational trending data or other information such as the number of motor starts. The majority of motor failures are not caused due to material design or quality issues, but rather by operational anomalies. Poorly trained personnel, along with the need to push machines beyond their design limits for increased production also contribute to the failure cycle. In many cases, excessive heating plays a significant role in the failure of A.C. induction motors. The move to integrated embedded sensors within the motor provides the ability to trend and view the operational and functional characteristics real time. The ability to embed several sensors that monitor key functional parameters coordinated with a dedicated microprocessor provides unparalleled monitoring and predictive information enabling the user to decrease the risk of unscheduled downtime. PART IV - INTEGRATED STRATEGY FOR EMBEDDED SENSORS In most processes, manufacturing and comfort applications, the sudden and unexpected failure of A.C. induction motors can cause significant process disruptions, leading to loss of productivity as well as profitability. As discussed, Reliability Based Maintenance strategies and technologies aid in the detection and prevention of unexpected motor failure. However these current methods require sophisticated instruments and highly trained personnel to implement this approach. In addition, most maintenance departments cannot monitor all of the motors within a given plant or facility. The cost in labor hours required to complete and maintain this task, would for most companies, be financially impossible. The combined decrease in cost and increase in the sophistication of sensors, intelligent algorithms, processing and memory power now makes the use of intelligent motors in industrial processes desirable. The placement of critical sensors to monitor vibration, flux, insulation and heating permits implementation of data analysis techniques. This results in the recording

of motor misuse or misapplication, which will aid in the estimation of motor life. This approach will compliment most current RBM strategies along with significantly increasing the coverage of A.C. induction motor monitoring to a level not currently covered by most maintenance strategies. The initial version of the intelligent motor will apply only to fixed speed sinewave A.C. induction motors. Variable frequency drive compatibility will follow in the next generation of intelligent motors. SYSTEM ARCHITECTURE

SENSOR ALLOCATION: QTY. DESCRIPTION 1 Vibration (motor frame, inside junction box) 1 Flux (axially in motor end bell) 1 Frame Temperature (inside junction box) 1 Winding Temperature Thermistor 1 Ambient Temperature Sensor 2 Bearing Temperature 2 Voltage 3 Insulation TOTAL: 12 Sensors SYSTEM OVERVIEW The heart of the intelligent motor is a 16-bit microprocessor with 14-bit a/d, 1 Mbytes RAM memory and 0.5 Mbytes of flash memory. The electrical components on the printed circuit boards are industrial grade and will withstand temperatures in excess of 85 degrees Celsius. Communication is via RS485 as

well RS232 and output data is viewed in a very user-friendly software environment. The specific nameplate motor data and additional design characteristics per each motor is loaded into the memory during the manufacturing process. The intelligent motors parameter values along with flux, vibration and voltage spectral data are processed and trended based on the measurement categories combined with fundamental alarm and advisory logic. Operational measurements are computed and trended through a combination of the vibration and flux sensors. Significant parameters that are measured and trended include: RPM Load Number of Starts Run Time RPM is calculated through a patented algorithm using vibration and flux measurements and is accurate within +/- 1 RPM. Motor load is then calculated based on slip, voltage and the motor's torque curve. Motor starts are detected and time stamped which provides for knowing the exact operational condition of the motor. Motor run time is also calculated and provided which assists in obtaining Mean Time to Repair (MTTR). Electrical components are monitored and trended by measuring the motor's electromagnetic field with the internal flux coil. High resolution Fast Fourier Transform (FFT) spectrum analysis of the flux field results in a flux signature containing valuable information related to electrical components of the motor including: Voltage Phase Imbalance Stator Turn to Turn Shorts Rotor Bar Condition Voltage imbalance as low as 3% would require that the motor be de-rated to approximately 85% of design load rating or suffer the consequences of premature motor failure. A severity indication related to any of these values is determined through comparison with detailed measurements of motor current spectrum at full load.

Mechanical components are monitored and trended by measuring the motor vibration through a radial vibration transducer. High resolution FFT spectrum analysis (up to 2500 Hz and 3200 lines) of the vibration signature will provide trend information related to: Balance Alignment Bearings Belts General System Problems High motor vibration is another major contributor that will shorten the life of the motor as well as cause catastrophic failure. Excessive temperature caused by either environmental or operational conditions can be detrimental to the motors operation and life. As previously stated, ambient, frame, winding and bearing temperatures are also monitored and trended. Proprietary designed insulation sensors are embedded during the winding process and will alert the user once 50% insulation life is achieved. Additionally, the intelligent motor incorporates two output contacts. These two contacts will close when a predefined hazardous event occurs, alerting the user through a Programmable Logic Controller, Distributed Control System or simply lighting a light in the maintenance office. This provides the user with immediate notification to any serious condition prior to failure. PART V - DIAGNOSTIC SOFTWARE Embedded sensors do not automatically equate to better information. The key to utilizing the sensors is in the user friendly and concise diagnostic software. Today's technology in many cases provides too much information for the end user. The information most users prefer is that which is provided in a summarized manner along with corresponding recommendations. This is accomplished in four steps: Simplistic summation of data retrieved from all sensors Viewing of multiple attributes simultaneously Operational trending data Diagnostic software recommendations developed by experience

The summation page shown in Figure 2 displays, in an easy-to-read format, each attribute gained from the embedded sensors with individual alarm indication. The key is to have a very quick review of the motor's overall health and to see what potential problems may have arisen. This summation minimizes the time for first review and allows maintenance to focus on problem motors, not conducting exhaustive diagnostics on healthy ones. The individual attributes alarm thresholds are present with historical data and may be changed by the user to meet their particular application or requirements.

Figure 2 The embedded sensors are read and time dated allowing comparison of different attributes to diagnose a particular problem. Using the advancements in Windows 95 software, multiple trends can be viewed simultaneously, see Figure 3. Using a drive end bearing failure as an example, an alarm indicating a high vibration in the bearing frequencies can be confirmed by displaying and comparing trends with the bearing temperature. The individual factory preset threshold alarm values are based on historical data achieved from embedded sensors. Diagnostic software give generic suggestions on the situation based on this history. As experience increases with the embedded sensors, so too will the easily upgraded software in its ability to give concise recommendations. This simplistic end user interface will allow for more efficient and proactive maintenance activities.

Figure 3 PART VI - SUMMARY AND CONCLUSIONS In today's global economy, the need to maintain production availability along with the pressures of decreased overhead while increasing profitability is changing the way maintenance is performed. We have discussed the multitude of stand alone, external technologies, which aid in the detection of motor failure. However, with the advent of intelligent motors, the benefits will far outweigh the initial capital costs by more effectively utilizing maintenance labor and most importantly, preventing unscheduled downtime. Finally, the technology that is now being applied into motors is just the first step in the proliferation of similar technology into other critical driven equipment such gearboxes, pumps, compressors, and fans. As the adoption rate increases, so too will the volumes, which will in turn reduce the cost. As seen with other microprocessor based products, the reduction in price will allow the integration of intelligent sensors into the lowest horsepower rating of motors and other critical components such as bearings. The final outcome will be further production capacity increases and most importantly increased revenues for those companies who embrace and implement Reliability Based Maintenance strategies inclusive of A.C. motors with embedded sensor technology. REFERENCES [1.] Austin H. Bonnett, "A Methodology for Root Cause AC Motor Failure Analysis". To be published, June 1999 EASA Convention. [2.] David G. Petersen, "The Business of Plant Maintenance". October 1995. [3.] Paul A. Wishnafski, "The Road to RBM: Implementation of a Reliability-Based Maintenance Program". Computational Systems Incorporated, 1997.

[4.] Stewart V. Bowers, III, Ph.D., "Implementing the Status Smart Sensor Technology into a Predictive and Proactive Maintenance Program". Computational Systems Incorporated, 1997. Copyright 1999, Computational Systems Incorporated. All rights reserved. All contents copyright 1998 - 2006, Computational Systems, Inc. All Rights Reserved.