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This paper introduces a sophisticated approach for identifying and categorizing broken rotor bars in direct torque-controlled (DTC) induction motors. DTC is implemented in industrial drive systems as a suitable control method to preserve torque control performance, which sometimes shows its impact on fault-representing frequencies. This is because of the DTC's closed-loop control nature, whichtriesto reduce speed and torque ripples by changing the voltage profile. The proposed model utilizes the modified Shapley Additive exPlanations (SHAP) technique in combination with gradient-boosting decision trees (GBDT) to detect and classify the abnormalities in BRBs at diverse (0%, 25%, 50%, 75%, and 100%) loading conditions. To prevent overfitting of the proposed model, we used the adaptive fold cross-validation (AF-CV) technique, which can dynamically adjust the number of folds during the optimization process. By employing extensive feature engineering in the original dataset and then applying Shapely Additive exPlanations(SHAP)-based feature selection, our methodology effectively identifies informative features from signals (three-phase current, three-phase voltage, torque, and speed) and motor characteristics. The gradient-boosting decision tree (GBDT) classifier, trained using the given characteristics, extracts consistent and reliable classification performance under different loading circumstances and enables precise and accurate detection and classification of broken rotor bars. The proposed approach (SHAP-Fusion GBDT with AF-CV) is a major advancement in the field of machine learning in detecting motor anomalies at varying loading conditions and proved to be an effective mechanism for preventative maintenance and preventing faults in DTC-controlled induction motors byattaining an accuracy rate of 99% for all loading conditions. [ABSTRACT FROM AUTHOR]

This paper introduces a sophisticated approach for identifying and categorizing broken rotor bars in direct torque-controlled (DTC) induction motors. DTC is implemented in industrial drive systems as a suitable control method to preserve torque control performance, which sometimes shows its impact on fault-representing frequencies. This is because of the DTC’s closed-loop control nature, whichtriesto reduce speed and torque ripples by changing the voltage profile. The proposed model utilizes the modified Shapley Additive exPlanations (SHAP) technique in combination with gradient-boosting decision trees (GBDT) to detect and classify the abnormalities in BRBs at diverse (0%, 25%, 50%, 75%, and 100%) loading conditions. To prevent overfitting of the proposed model, we used the adaptive fold cross-validation (AF-CV) technique, which can dynamically adjust the number of folds during the optimization process. By employing extensive feature engineering in the original dataset and then applying Shapely Additive exPlanations(SHAP)-based feature selection, our methodology effectively identifies informative features from signals (three-phase current, three-phase voltage, torque, and speed) and motor characteristics. The gradient-boosting decision tree (GBDT) classifier, trained using the given characteristics, extracts consistent and reliable classification performance under different loading circumstances and enables precise and accurate detection and classification of broken rotor bars. The proposed approach (SHAP-Fusion GBDT with AF-CV) is a major advancement in the field of machine learning in detecting motor anomalies at varying loading conditions and proved to be an effective mechanism for preventative maintenance and preventing faults in DTC-controlled induction motors byattaining an accuracy rate of 99% for all loading conditions.

The contribution of rotor bar fault diagnosis and classification in low-speed induction motor drives under varying load torques has been a topic of limited discussion in the literature. Within this respect, the present paper will be discussing this condition. To ensure control performance and investigate the diagnosis process in low-speed operations, the backstepping algorithm is utilized to handle uncertainties. The discrete wavelet transform is employed to detect faults and decompose signals at various levels, while the fuzzy logic algorithm is applied to classify the fault severity. This study's novelty lies in evaluating fault severity for no/low-load conditions by using the energy approximation obtained from the discrete wavelet transforms of the speed regulator's output signal. This approximation is then used as input for the fuzzy fault classification algorithm. The control algorithm and fault diagnosis are validated experimentally using MATLAB/Simulink with a real-time interface based on dSpace 1104 implementation. The results obtained from this procedure demonstrate successful fault detection and severity classification using both the discrete wavelet approximation and its energy eigenvalue. [ABSTRACT FROM AUTHOR]

The lifetime of induction motors can be significantly extended by installing diagnostic systems for monitoring their operating conditions. In particular, detecting broken bar failures in motors is important for avoiding the risk of short circuits or other accidents with serious consequences. In the literature, many approaches have been proposed for motor fault detection; however, additional generalized methods based on local and statistical analysis could provide a low-complexity and feasible solution in this field of research. The proposed work presents a methodology for detecting one or two broken rotor bars using the sums and differences histograms (SDH) and machine learning classifiers in this context. From the SDH computed in one phase of the motor's current, nine texture features are calculated for different displacements. Then, all features are used to train two classifiers and to find the best displacements for faults and health identification in the induction motors. A final experimental evaluation considering the best displacements shows an accuracy of 98.16 % for the homogeneity feature and a few signal samples used in a decision tree classifier. Additionally, a polynomial regression curve validates the use of 50 samples to obtain an accuracy of 88.15 % , whereas the highest performance is achieved for 250 samples. [ABSTRACT FROM AUTHOR]

This work presents a new Fault Tolerant Control approach for a doubly fed induction generator using Iterative Learning Control when the fault occurs. The goal of this research is to apply the proposed ILC controller in conjunction with vector control for doubly fed induction generator to enhance its reliability and availability under broken rotor bars. However, the performances of classical VC control are often characterized by their inability to deal with the effects of faults. To overcome these drawbacks, a combination of VC control and iterative learning control is described. The input control signal of the VC controller is gradually regulated by the ILC harmonic compensator in order to eliminate the faults effect. The improvement of this approach related to active and reactive power ripples overshoot and response time have been explained. Which active and reactive power response time have been reduced more than 84% and 87.5 % respectively. The active and reactive power overshoots have been reduced about 45% and 35% respectively. The obtained results emphasize the efficiency and the ability of the proposed FTC to enhance the power quality in faulty condition. [ABSTRACT FROM AUTHOR]

Induction motors are indispensable, robust, and reliable machines for industry; however, as with any machine, they are susceptible to diverse faults. Among the faults that a motor can suffer, broken rotor bars (BRBs) have become one of the most studied ones because the motor under this fault condition can continue operating with apparent normality, yet the fault severity can quickly increase and, consequently, generate the whole collapse of the motor, raising repair costs and the risk to people or other machines around it. This work proposes an expert system to detect BRB early, i.e., half-BRB, 1-BRB, and 2-BRB, from the current signal analysis by considering the following two operating regimes: start-up transient and steady-state. The method can diagnose the BRB condition by using either one regime or both regimes, where the objective is to somehow increase the reliability of the result. Regarding the proposed expert system, it consists of the application of two autoencoders, i.e., one per regime, to diagnose the BRB condition. To automatically separate the regimes of analysis and obtain the envelope of the current signal, the Hilbert transform is applied. Then, the particle swarm optimization method is implemented to compute the separation point of both regimes in the current signal. Once the signal is separated, the two autoencoders and a simple set of if-else rules are employed to automatically determine the BRB condition. The proposed expert system proved to be an effective tool, with 100% accuracy in diagnosing all BRB conditions. [ABSTRACT FROM AUTHOR]

Due to their robustness, versatility and performance, induction motors (IMs) have been widely used in many industrial applications. Despite their characteristics, these machines are not immune to failures. In this sense, breakage of the rotor bars (BRB) is a common fault, which is mainly related to the high currents flowing along those bars during start-up. In order to reduce the stresses that could lead to the appearance of these faults, the use of soft starters is becoming usual. However, these devices introduce additional components in the current and flux signals, affecting the evolution of the fault-related patterns and so making the fault diagnosis process more difficult. This paper proposes a new method to automatically classify the rotor health state in IMs driven by soft starters. The proposed method relies on obtaining the Persistence Spectrum (PS) of the start-up stray-flux signals. To obtain a proper dataset, Data Augmentation Techniques (DAT) are applied, adding Gaussian noise to the original signals. Then, these PS images are used to train a Convolutional Neural Network (CNN), in order to automatically classify the rotor health state, depending on the severity of the fault, namely: healthy motor, one broken bar and two broken bars. This method has been validated by means of a test bench consisting of a 1.1 kW IM driven by four different soft starters coupled to a DC motor. The results confirm the reliability of the proposed method, obtaining a classification rate of 100.00% when analyzing each model separately and 99.89% when all the models are analyzed at a time. [ABSTRACT FROM AUTHOR]

Due to their starting and running torque needs as well as their four-quadrant operation, modern industrial drives utilise induction motors (IM). Failures in the rotor bars of the motor can be found using the voltages and currents of each of the three phases as well as the acceleration and velocity signals. For the diagnosis of the quantity of broken rotor bars for a failed IM, conventional signal processing-based feature extraction techniques and machine learning algorithms have been applied in the past. The number of broken rotor bars is determined in this study by looking into a novel technique. For the aforementioned aims, specifically, the deep learning methodologies are studied. In order to do this, convolutional neural network (CNN) transfer learning algorithms are described. Initially, a bandpass filter is used for denoising, and then the signals are transformed using the continuous wavelet transform to create time-frequency pictures (CWT). The collected images are used for deep feature extraction and classification using the support vector machine (SVM) classifier, as well as for fine-tuning the pre-trained ResNet18 model. Metrics for performance evaluation employ categorization accuracy. Additionally, the results demonstrate that the deep features that are recovered from the mechanical vibration signal and current signal yield the greatest accuracy score of 100%. Nonetheless, a performance comparison with the publicly available techniques is also done. The comparisons also demonstrate that the proposed strategy outperforms the compared methods in terms of accuracy scores. [ABSTRACT FROM AUTHOR]

This review paper looks briefly at conventional approaches and examines the intelligent means for fault diagnosis (FD) and condition monitoring (CM) of electrical drives in detail, especially the ones that are common in Industry 4.0. After giving an overview on fault statistics, standard methods for the FD and CM of rotating machines are first visited, and then its orientation towards intelligent approaches is discussed. Major diagnostic procedures are addressed in detail together with their advancements to date. In particular, the emphasis is given to motor current signature analysis (MCSA) and digital signal processing techniques (DSPTs) mostly used for feature engineering. Consequently, the statistical procedures and machine learning techniques (stemming from artificial intelligence—AI) are also visited to describe how FD is carried out in various systems. The effectiveness of the amalgamation of the model, signal, and data-based techniques for the FD and CM of inductions motors (IMs) is also highlighted in this review. It is worth mentioning that a variety of neural- and non-neural-based approaches are discussed concerning major faults in rotating machines. Finally, after a thorough survey of the diagnostic techniques based on specific faults for electrical drives, several open problems are identified and discussed. The paper concludes with important recommendations on where to divert the research focus considering the current advancements in the FD and CM of rotating machines. [ABSTRACT FROM AUTHOR]

Knowledge of the distinctive frequencies and amplitudes of broken rotor bar (BRB) faults in the induction motor (IM) is essential for most fault diagnosis methods. Fast Fourier transform (FFT) is widely applied to diagnose the faults within BRBs. However, this method does not provide satisfactory results if it is applied directly to the stator current signal at low slip because a high-resolution spectrum is required to separate the different components of the frequency. To address this problem, this paper proposes an efficient method based on a Hilbert fast Fourier transform (HFFT) approach, which is used to extract the envelope from the stator current using the Hilbert transform (HT) at low slip. Then, the stator current envelope is analyzed using the fast Fourier transform (FFT) to obtain the amplitude and frequency of the particular harmonic. These data were recently collected and selected as BRB fault features and were employed as adaptive neuro-fuzzy inference system (ANFIS) inputs for BRB fault autodiagnosis and classification. To identify the BRB defect by determining the number of broken bars in the rotor, two ANFIS models are proposed: ANFIS grid partitioning (ANFIS-GP) and ANFIS-subtractive clustering (ANFIS-SC). To validate the effectiveness of the proposed method, three different motors were used during experiments under various loads; the first was with one broken bar, the second was with two adjacent broken bars, and the third was a healthy motor. The obtained results confirmed the effectiveness and the robustness of the proposed method, which is based on the combination of HFFT-ANFIS-SC to diagnose the BRB faults and quantify the number of broken bars under different load conditions (under low and high slip) precisely with minimal errors (this method had an MSE of 10-14 and 10-7 for the RMSE) compared to the method based on the combination of HFFT-ANFIS-GP. [ABSTRACT FROM AUTHOR]

The lifetime of induction motors can be significantly extended by installing diagnostic systems for monitoring their operating conditions. In particular, detecting broken bar failures in motors is important for avoiding the risk of short circuits or other accidents with serious consequences. In the literature, many approaches have been proposed for motor fault detection; however, additional generalized methods based on local and statistical analysis could provide a low-complexity and feasible solution in this field of research. The proposed work presents a methodology for detecting one or two broken rotor bars using the sums and differences histograms (SDH) and machine learning classifiers in this context. From the SDH computed in one phase of the motor’s current, nine texture features are calculated for different displacements. Then, all features are used to train two classifiers and to find the best displacements for faults and health identification in the induction motors. A final experimental evaluation considering the best displacements shows an accuracy of 98.16% for the homogeneity feature and a few signal samples used in a decision tree classifier. Additionally, a polynomial regression curve validates the use of 50 samples to obtain an accuracy of 88.15%, whereas the highest performance is achieved for 250 samples.

Induction motors (IMs) have been extensively used for driving a wide variety of processes in several industries. Their excellent performance, capabilities and robustness explain their extensive use in several industrial applications. However, despite their robustness, IMs are susceptible to failure, with broken rotor bars (BRB) being one of the potential faults. These types of faults usually occur due to the high current amplitude flowing in the bars during the starting transient. Currently, soft-starters have been used in order to reduce the negative effects and stresses developed during the starting. However, the addition of these devices makes the fault diagnosis a complex and sometimes erratic task, since the typical fault-related patterns evolutions are usually irregular, depending on particular aspects that may change according to the technology implemented by the soft-starter. This paper proposes a novel methodology for the automatic detection of BRB in IMs under the influence of soft-starters. The proposal relies on the combined analysis of current and stray flux signals by means of suitable indicators proposed here, and their fusion through a linear discriminant analysis (LDA). Finally, the LDA output is used to train a feed-forward neural network (FFNN) to automatically detect the severity of the failure, namely: a healthy motor, one broken rotor bar, and two broken rotor bars. The proposal is validated under a testbench consisting of a kinematic chain driven by a 1.1 kW IM and using four different models of soft-starters. The obtained results demonstrate the capabilities of the proposal, obtaining a correct classification rate (94.4% for the worst case). [ABSTRACT FROM AUTHOR]

Summary: The present paper proposes a detection method of the broken rotor bar fault in an induction motor at low‐speed operation. The diagnosis method is based at the first place, on Hilbert Transform (HT) that is used to extract the stator current envelope; then on Discrete Wavelet Transform (DWT) which processes the previously produced signal. As such, the calculation of the stored energy on envelope levels allows to determine the severity of the fault. In this work, the induction motor is controlled at the very low‐speed range and rated load via using sensorless Backstepping control. This nonlinear control is executed to preserve a satisfactory performance speed control during the presence of broken rotor bars to ensure operational continuity. Moreover, Model Reference Adaptive System (MRAS) is used for speed reconstruction to improve the control's system reliability and to reduce its cost. Considerably, through the use of simulation and real‐time implementation using MATLAB/Simulink with the dSpace 1104 control board, the effectiveness of the diagnosis and control techniques is evaluated. [ABSTRACT FROM AUTHOR]

The induction motors (IMs) are undoubtedly the most used machines in industries because of the advantages they offer such as simplicity, service continuity and low cost. Due to wear and tear, the motor suffers different types of mechanical and electrical failures. Depending on the criticality of the plant motors, it could be necessary to implement predictive techniques in order to detect the faults before they can cause unnecessary downtime. Therefore, in this paper, the research approach was to develop a low cost measurement system based on a micro controller platform for machine diagnosis. The FRDM K64F developing board was selected as the most suitable for satisfying the system conditions, and it was used to collect induction motor`s current data. In order to validate the accuracy of the developed system, the Frequency Transfer Functions (FRF) of the developed measurement system and the standard system (NI USB-6009) were compare. It showed a flat frequency spectrum from 0 to 1 KHz, with small fluctuations of about 0.25 dB standard deviation. A fully automated test bench was implemented, which allows to perform all the measurement tests with the IMs, and in this case, the detection and diagnosis of broken bars. Around 240 tests were performed with varying loads, different rotation speeds, and with different severity damage levels in the rotor. The data analysis procedure for broken rotor bar detection and motor diagnosis was performed by the Motor Current Signature Analysis (MCSA), FFT and Enveloped Analysis (EA). Finally, the research approach was successfully accomplished, by the team by developing a software firmware measurement ultra-low cost development platform for machine diagnosis. It was also developed a proper antialiasing filter to reduce industrial noise. The effectiveness of the proposed system is detecting a weak fault in a noise signal. It was found out a new consistent and robust parameter called the pole pass frequency (fpsf), which could be used as a diagnosis parameter for detection of broken rotor bars faults, with their damage severity degree. The detected parameter can be found around 2.6 Hz, and it increases in amplitude with increasing damage severity.

Induction motors are indispensable, robust, and reliable machines for industry; however, as with any machine, they are susceptible to diverse faults. Among the faults that a motor can suffer, broken rotor bars (BRBs) have become one of the most studied ones because the motor under this fault condition can continue operating with apparent normality, yet the fault severity can quickly increase and, consequently, generate the whole collapse of the motor, raising repair costs and the risk to people or other machines around it. This work proposes an expert system to detect BRB early, i.e., half-BRB, 1-BRB, and 2-BRB, from the current signal analysis by considering the following two operating regimes: start-up transient and steady-state. The method can diagnose the BRB condition by using either one regime or both regimes, where the objective is to somehow increase the reliability of the result. Regarding the proposed expert system, it consists of the application of two autoencoders, i.e., one per regime, to diagnose the BRB condition. To automatically separate the regimes of analysis and obtain the envelope of the current signal, the Hilbert transform is applied. Then, the particle swarm optimization method is implemented to compute the separation point of both regimes in the current signal. Once the signal is separated, the two autoencoders and a simple set of if-else rules are employed to automatically determine the BRB condition. The proposed expert system proved to be an effective tool, with 100% accuracy in diagnosing all BRB conditions.

Due to their robustness, versatility and performance, induction motors (IMs) have been widely used in many industrial applications. Despite their characteristics, these machines are not immune to failures. In this sense, breakage of the rotor bars (BRB) is a common fault, which is mainly related to the high currents flowing along those bars during start-up. In order to reduce the stresses that could lead to the appearance of these faults, the use of soft starters is becoming usual. However, these devices introduce additional components in the current and flux signals, affecting the evolution of the fault-related patterns and so making the fault diagnosis process more difficult. This paper proposes a new method to automatically classify the rotor health state in IMs driven by soft starters. The proposed method relies on obtaining the Persistence Spectrum (PS) of the start-up stray-flux signals. To obtain a proper dataset, Data Augmentation Techniques (DAT) are applied, adding Gaussian noise to the original signals. Then, these PS images are used to train a Convolutional Neural Network (CNN), in order to automatically classify the rotor health state, depending on the severity of the fault, namely: healthy motor, one broken bar and two broken bars. This method has been validated by means of a test bench consisting of a 1.1 kW IM driven by four different soft starters coupled to a DC motor. The results confirm the reliability of the proposed method, obtaining a classification rate of 100.00% when analyzing each model separately and 99.89% when all the models are analyzed at a time.

Deep learning-based fault detection approach for squirrel cage induction motors (SCIMs) fault detection can provide a reliable solution to the industries. This paper encapsulates the idea of transfer learning-based knowledge transfer approach and deep convolutional neural network (dCNN) to develop a novel fault detection framework for multiple and simultaneous fault detection in SCIM. In comparison with the existing techniques, transfer learning-based deep CNN (TL-dCNN) method facilitates faster training and higher accuracy. The current signals acquired with the help of hall sensors and converted to an image for input to the TL-dCNN model. This approach provides autonomous learning of features and decision-making with minimum human intervention. The developed method is also compared to the existing state-of-the-art techniques, and it outperforms them and has an accuracy of 99.40%. The dataset for the TL-dCNN model is generated from the experimental setup and programming is done in python with the help of Keras and TensorFlow packages. [ABSTRACT FROM AUTHOR]

Copyright of Przegląd Elektrotechniczny is the property of Przeglad Elektrotechniczny and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

It is important to detect the faults of induction motors in an accurate manner due to their widespread use in industrial production processes. Broken rotor bars and eccentricity faults are the common faults of induction motor. The simultaneous occurrence of these two types of faults is often encountered in industrial facilities. Therefore, it is important to properly detect characteristic harmonic components of these types of faults. It is difficult to detect these components at low loading and noisy conditions. In this paper, the simultaneous broken rotor bars and static eccentricity faults are investigated based on the stator current and vibration signals. Hilbert envelope analysis was applied to the stator current and vibration signals under four different loading levels (25%, 50%, 75% and 100%) of induction motor. The frequencies and amplitudes of characteristic harmonic components have been successfully detected in envelope spectrum. The results show that the proposed method can be used to diagnose the simultaneous broken rotor bars and eccentricity faults of induction motors. [ABSTRACT FROM AUTHOR]

Knowledge of the distinctive frequencies and amplitudes of broken rotor bar (BRB) faults in the induction motor (IM) is essential for most fault diagnosis methods. Fast Fourier transform (FFT) is widely applied to diagnose the faults within BRBs. However, this method does not provide satisfactory results if it is applied directly to the stator current signal at low slip because a high-resolution spectrum is required to separate the different components of the frequency. To address this problem, this paper proposes an efficient method based on a Hilbert fast Fourier transform (HFFT) approach, which is used to extract the envelope from the stator current using the Hilbert transform (HT) at low slip. Then, the stator current envelope is analyzed using the fast Fourier transform (FFT) to obtain the amplitude and frequency of the particular harmonic. These data were recently collected and selected as BRB fault features and were employed as adaptive neuro-fuzzy inference system (ANFIS) inputs for BRB fault autodiagnosis and classification. To identify the BRB defect by determining the number of broken bars in the rotor, two ANFIS models are proposed: ANFIS grid partitioning (ANFIS-GP) and ANFIS-subtractive clustering (ANFIS-SC). To validate the effectiveness of the proposed method, three different motors were used during experiments under various loads; the first was with one broken bar, the second was with two adjacent broken bars, and the third was a healthy motor. The obtained results confirmed the effectiveness and the robustness of the proposed method, which is based on the combination of HFFT-ANFIS-SC to diagnose the BRB faults and quantify the number of broken bars under different load conditions (under low and high slip) precisely with minimal errors (this method had an MSE of 10-14 and 10-7 for the RMSE) compared to the method based on the combination of HFFT-ANFIS-GP.

Abstract A precise detection of the fault feature parameter of motor current is a new research hotspot in the broken rotor bar (BRB) fault diagnosis of induction motors. Discrete Fourier transform (DFT) is the most popular technique in this field, owing to low computation and easy realization. However, its accuracy is often limited by the data window length, spectral leakage, fence effect, etc. Therefore, a new detection method based on a global optimization algorithm is proposed. First, a BRB fault current model and a residual error function are designed to transform the fault parameter detection problem into a nonlinear least-square problem. Because this optimization problem has a great number of local optima and needs to be resolved rapidly and accurately, a joint algorithm (called TR-MBPSO) based on a modified bare-bones particle swarm optimization (BPSO) and trust region (TR) is subsequently proposed. In the TR-MBPSO, a reinitialization strategy of inactive particle is introduced to the BPSO to enhance the swarm diversity and global search ability. Meanwhile, the TR is combined with the modified BPSO to improve convergence speed and accuracy. It also includes a global convergence analysis, whose result proves that the TR-MBPSO can converge to the global optimum with the probability of 1. Both simulations and experiments are conducted, and the results indicate that the proposed detection method not only has high accuracy of parameter estimation with short-time data window, e.g., the magnitude and frequency precision of the fault-related components reaches 10−4, but also overcomes the impacts of spectral leakage and non-integer-period sampling. The proposed research provides a new BRB detection method, which has enough precision to extract the parameters of the fault feature components.

Induction motors (IMs) have been extensively used for driving a wide variety of processes in several industries. Their excellent performance, capabilities and robustness explain their extensive use in several industrial applications. However, despite their robustness, IMs are susceptible to failure, with broken rotor bars (BRB) being one of the potential faults. These types of faults usually occur due to the high current amplitude flowing in the bars during the starting transient. Currently, soft-starters have been used in order to reduce the negative effects and stresses developed during the starting. However, the addition of these devices makes the fault diagnosis a complex and sometimes erratic task, since the typical fault-related patterns evolutions are usually irregular, depending on particular aspects that may change according to the technology implemented by the soft-starter. This paper proposes a novel methodology for the automatic detection of BRB in IMs under the influence of soft-starters. The proposal relies on the combined analysis of current and stray flux signals by means of suitable indicators proposed here, and their fusion through a linear discriminant analysis (LDA). Finally, the LDA output is used to train a feed-forward neural network (FFNN) to automatically detect the severity of the failure, namely: a healthy motor, one broken rotor bar, and two broken rotor bars. The proposal is validated under a testbench consisting of a kinematic chain driven by a 1.1 kW IM and using four different models of soft-starters. The obtained results demonstrate the capabilities of the proposal, obtaining a correct classification rate (94.4% for the worst case).

Copyright of Technisches Messen is the property of De Gruyter and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Abstract In spectrum analysis of induction motor current, the characteristic components of broken rotor bars (BRB) fault are often submerged by the fundamental component. Although many detection methods have been proposed for this problem, the frequency resolution and accuracy are not high enough so that the reliability of BRB fault detection is affected. Thus, a new multiple signal classification (MUSIC) algorithm based on particle swarm intelligence search is developed. Since spectrum peak search in MUSIC is a multimodal optimization problem, an improved bare-bones particle swarm optimization algorithm (IBPSO) is proposed first. In the IBPSO, a modified strategy of subpopulation determination is introduced into BPSO for realizing multimodal search. And then, the new MUSIC algorithm, called IBPSO-based MUSIC, is proposed by replacing the fixed-step traversal search with IBPSO. Meanwhile, a simulation signal is used to test the effectiveness of the proposed algorithm. The simulation results show that its frequency precision reaches 10−5, and the computational cost is only comparable to that of traditional MUSIC with 0.1 search step. Finally, the IBPSO-based MUSIC is applied in BRB fault detection of an induction motor, and the effectiveness and superiority are proved again. The proposed research provides a modified MUSIC algorithm which has sufficient frequency precision to detect BRB fault in induction motors.

This article presents a novel approach for detecting broken rotor bars in squirrel-cage induction motors, using a time-domain current analysis. More particularly, this solution proposes a new use of histogram of oriented gradients since this method is usually applied in computer vision and image processing applications. Fully broken rotor bars have been detected when the motor was running at a very low slip since this operational condition is very difficult to identify using the traditional motor-current signature analysis. In addition, only one phase of the stator current of the machine was applied to extract the intensity gradients and edge directions of each current time window, for both healthy and damaged rotors. It is important to highlight that the present method does not require the slip measurement for fault detection, as demand for other techniques and often related to false negative indications. The features extracted from the histograms have been applied as inputs for a neural network classifier. This method has been validated using some experimental data from a 7.5-kW squirrel-cage induction machine running at distinct load levels (slip conditions) and also for oscillatory loads. [ABSTRACT FROM AUTHOR]

Abstract—At present, one of the most effective methods for detecting dangling bars in squirrel-cage rotor windings of induction motors operating under severe starting conditions is the spectral analysis of stator current in a steady-state operation mode. The existing methods of testing in starting modes are not sensitive enough or their study has not been completed, although it is precisely such methods that allow diagnostics of machines that cannot be inspected in the steady-state operation mode. The purpose of this article is to develop a method for monitoring the state of rotor windings in induction motors operating under severe starting conditions based on the stator current in the starting mode, which is an urgent task. The studies were carried out both on digital models of an induction motor, developed in the Ansys software package, and on an experimental stand with a low voltage supplied to a low-voltage motor to increase the duration of its start. Signal processing is performed in the Matlab software package using the short-time Fourier transform. It is shown that only in the presence of a broken rotor bar, the amplitude of the harmonic component of the order coinciding with the number of motor pole pairs sharply increases at the lower side frequency; this indicates the presence of damage. It is shown that the developed technique for monitoring the condition of rotor windings in induction motors operating under severe starting conditions is more sensitive to broken rotor bars than the existing methods; this makes it possible to timely detect damage to rotor windings and prevent sudden failures of induction motors. [ABSTRACT FROM AUTHOR]

Reliable induction motor (IM) fault detection techniques are very useful in industries to diagnose IM defects and improve operational performance. A smart sensor-based technology is proposed in this article to synergistically use vibration and current harmonics for rotor bar fault detection in IMs. The vibration signal is used for analysis of shaft speed variations and the current harmonics information is applied for rotor bar fault detection. A wireless smart sensor network is developed and used for data collection, allowing for low-cost, low space footprint, and noninvasive installation. The effectiveness of the proposed synergistic technique is examined experimentally, with results demonstrating advantages over conventional methods in terms of accurately differentiating between a healthy and faulty motor, as well as estimating the fault severity, even under zero-load IM conditions. A means to quantify the fault states as diagnostic indices is also proposed for online IM health condition monitoring. [ABSTRACT FROM AUTHOR]

Induction motors (IM) are key components of any industrial process; hence, it is important to carry out continuous monitoring to detect incipient faults in them in order to avoid interruptions on production lines. Broken rotor bars (BRBs), which are among the most regular and most complex to detect faults, have attracted the attention of many researchers, who are searching for reliable methods to recognize this condition with high certainty. Most proposed techniques in the literature are applied during the IM startup transient, making it necessary to develop more efficient fault detection techniques able to carry out fault identification during the IM steady state. In this work, a novel methodology based on motor current signal analysis and contrast estimation is introduced for BRB detection. It is worth noting that contrast has mainly been used in image processing for analyzing texture, and, to the best of the authors’ knowledge, it has never been used for diagnosing the operative condition of an induction motor. Experimental results from applying the approach put forward validate Unser and Tamura contrast definitions as useful indicators for identifying and classifying an IM operational condition as healthy, one broken bar (1BB), or two broken bars (2BB), with high certainty during its steady state.

This article presents a novel approach for detecting broken rotor bars in squirrel-cage induction motors, using a time-domain current analysis. More particularly, this solution proposes a new use of histogram of oriented gradients since this method is usually applied in computer vision and image processing applications. Fully broken rotor bars have been detected when the motor was running at a very low slip since this operational condition is very difficult to identify using the traditional motor-current signature analysis. In addition, only one phase of the stator current of the machine was applied to extract the intensity gradients and edge directions of each current time window, for both healthy and damaged rotors. It is important to highlight that the present method does not require the slip measurement for fault detection, as demand for other techniques and often related to false negative indications. The features extracted from the histograms have been applied as inputs for a neural network classifier. This method has been validated using some experimental data from a 7.5-kW squirrel-cage induction machine running at distinct load levels (slip conditions) and also for oscillatory loads. [ABSTRACT FROM AUTHOR]

In this paper a Passive Fault Tolerant Control (PFTC) based on non-linear backstepping control is proposed for a Double Star Induction Machine (DSIM) under Broken Rotor Bars (BRB) fault of a squirrel-cage in order to improve its reliability and availability. The proposed PFTC is able to maintain acceptable performance in the event of BRB. This control technique guarantees robustness against uncertainties and external disturbances and is also able to deal directly with faults by compensating for the effects of the BRB fault in the machine without prior knowledge on the fault, its location and its severity. The stability of the closed-loop is verified by the exploitation of the Lyapunov theory. a comparative study is made between the proposed Fault Tolerance Control (FTC) and Sliding Mode Control (SMC) for demonstrating the performance and effectiveness of the proposed controller. The results obtained show that the proposed FTC has a better robustness against the BRB fault where the DSIM operates with acceptable performance in both speed and torque. [ABSTRACT FROM AUTHOR]

This paper proposes a novel approach for simultaneous state estimation and broken rotor bars (BRBs) detection in induction motors. The proposed method is named square-root transformed cubature quadrature Kalman filter (SR-TCQKF). The accuracy of the filter has been improved by a transformation on the filter's sigma points, whereas the filter becomes more stable due to the use of the SR version of the covariance matrix. Accordingly, the SR-TCQKF is more accurate and stable than the standard cubature quadrature Kalman filter. The efficiency of the SR-TCQKF has been evaluated for speed estimation and BRB detection in induction motors. The attained results show the efficiency of the proposed approach. [ABSTRACT FROM AUTHOR]

This paper presents some considerations regarding the application of the stator zero-sequence current component (ZSC) in the fault detection of cage induction machines, including the effects of magnetic core saturation. Faults such as rotor cage asymmetry and static, dynamic, and mixed eccentricity were considered. The research started by developing a harmonic motor model, which allowed us to obtain a voltage equation for the zero-sequence current component. The equation allowed us to extract formulas of typical frequencies for particular fault types. Next, in order to verify the effectiveness of ZSC in induction motor fault diagnosis, finite element calculations and laboratory tests were carried out for the previously mentioned faults for delta and wye connections with neutral wire stator winding configurations.

Non-invasive diagnostic methods for electric machines’ diagnostics, which can be used during their operation in a drive system, are needed in many branches of the production industry. For the reliable condition assessment of electric machines, especially those operating in drive systems, various tools and methods have been suggested. One diagnostic method that has not been fully recognized and documented is a diagnostic method based on zero-sequence voltage component (ZSV) applications for the condition assessment of induction machines. In this paper, the application of ZSV in induction machine diagnostics is proposed. A factor that speaks in favor of applying this signal in such diagnostics is the high sensitivity of the signal to damage occurrence, and the distinct change of extracted symptoms in the case of asymmetry. It is possible to obtain a high signal amplitude, which simplifies its processing and the elaboration of reliable diagnostic factors. This ZSV-based method is also able to be applied to big machines used in industry. Due to the saturation effects visible in the ZSV signal, new diagnostic symptoms can appear, which allows for an easier condition assessment of certain machines. The usefulness of the described diagnostic method in machine condition assessment was shown through an equivalent circuit modeling process, finite element analysis, and laboratory tests of the machine.

Although induction motors (IMs) are robust and reliable electrical machines, they can suffer different faults due to usual operating conditions such as abrupt changes in the mechanical load, voltage, and current power quality problems, as well as due to extended operating conditions. In the literature, different faults have been investigated; however, the broken rotor bar has become one of the most studied faults since the IM can operate with apparent normality but the consequences can be catastrophic if the fault is not detected in low-severity stages. In this work, a methodology based on convolutional neural networks (CNNs) for automatic detection of broken rotor bars by considering different severity levels is proposed. To exploit the capabilities of CNNs to carry out automatic image classification, the short-time Fourier transform-based time–frequency plane and the motor current signature analysis (MCSA) approach for current signals in the transient state are first used. In the experimentation, four IM conditions were considered: half-broken rotor bar, one broken rotor bar, two broken rotor bars, and a healthy rotor. The results demonstrate the effectiveness of the proposal, achieving 100% of accuracy in the diagnosis task for all the study cases.

A method for diagnostics of the induction motor rotor bar breaks, based on the wavelet-analysis of the electromotive force induced in the stator windings in the rundown mode is developed. A method for decomposition of the electromotive force of the stator winding phase to the electromotive force signals of the active sides of winding coils using Z-transformation theory is developed. The effectiveness of the proposed diagnostic method was experimentally confirmed.

The induction motor current is nonstationary by nature, and time-scale analysis techniques such as wavelet packet decomposition (WPD) are more suitable for the analysis of the stator current for broken rotor bar detection. But, WPD is very costly in terms of the computational effort when half-band FIR filter banks are used in analysis. The implementation of four-band FIR filter banks in the analysis of a phase current is proposed here to reduce the computational cost. The use of four-band FIR filter banks with FPGA implementation would also provide higher levels of parallel processing capability resulting in further reduction in computational time required for detection of broken rotor bar faults. In WPD, it is also possible to tailor the frequency band size (resolution) so that one frequency band covers all motor fault induced frequencies due to rotor speed variations. Here, the rms value for broken rotor bar fault-related frequency band is compared with the baseline data to detect any broken rotor bar faults. [ABSTRACT FROM AUTHOR]

Squirrel-cage induction motors are widely used in a number of applications throughout the world. This paper proposes a neuro-fuzzy approach to identify and to classify a typical fault related to the induction motor damage, such as broken rotor bars. Two fuzzy classifiers are obtained by an adaptive-network-based fuzzy inference system model whose parameters can be identified by using the hybrid learning algorithm. A Hall effect sensor was installed between two stator slots of the induction machine, and a magnetic flux density variation is measured according to the failure. The data from the Hall sensor were used to extract some harmonic components by applying fast Fourier transform. Thus, some frequencies and their amplitudes were considered as inputs for the proposed fuzzy model to detect not only adjacent broken bars, but also noncontiguous faulted scenarios. In the present work it is not necessary to estimate the rotor slip, as required by the traditional condition monitoring technique, known as motor current signature analysis. This method was able to detect broken bars for induction motor running at low-load or no-load condition. The intelligent approach was validated using some experimental data from a 7.5-kW squirrel-cage induction machine. [ABSTRACT FROM AUTHOR]

This paper presents a methodology for the broken rotor bars fault detection is considered when the rotor speed varies continuously and the induction machine is controlled by Field-Oriented Control (FOC). The rotor fault detection is obtained by analyzing a several mechanical and electrical quantities (i.e., rotor speed, stator phase current and output signal of the speed regulator) by the Discrete Wavelet Transform (DWT) in variable speed drives. The severity of the fault is obtained by stored energy calculation for active power signal. Hence, it can be a useful solution as fault indicator. The FOC is implemented in order to preserve a good performance speed control; to compensate the broken rotor bars effect in the mechanical speed and to ensure the operation continuity and to investigate the fault effect in the variable speed. The effectiveness of the technique is evaluated in simulation and in a real-time implementation by using Matlab/Simulink with the real-time interface (RTI) based on dSpace 1104 board. [ABSTRACT FROM AUTHOR]

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This paper proposes the use of a Hall effect sensor installed between two stator slots of a squirrel cage induction motor, spectral analysis of the air gap disturbances and machine learning approaches for diagnosing fully broken rotor bars in motors running at very low slip. This paper overcomes a typical drawback of broken bars diagnosis by using the traditional analysis of the motor current signature, usually when machines operate under low or no-load conditions. A fast Fourier transform has been performed in Hall sensor data to identify some harmonic features, and also, some statistical data have been extracted to get time-domain properties. These values were used as inputs for a multilayer perceptron (MLP) neural network classifier, a k-nearest neighbor classifier, and a support vector machine classification technique. In addition, principal component analysis has been applied to reduce data dimension among some original values, i.e., for both time and frequency features, and contribute to rotor failure detection. A cross-validation method has been used for classifier performance evaluation on each case. The efficiency of this approach was evaluated from a 7.5-kW squirrel cage induction machine running at very low slip conditions, and MLP classifier has achieved better results than the other intelligent methods. [ABSTRACT FROM PUBLISHER]

This paper deals with the problem of fault detection in induction motors using the discrete wavelet transform (DWT) method. The DWT is a mathematical method used to extract different frequency components from a given signal. It is based on the decomposition of the processed signals into wavelet approximation and detail coefficients. In order to detect inter-turns short-circuit (ITSC) and broken rotor bars (BRBs) faults, the DWT is applied on two different signals: the current envelope and the current Park’s vector modulus. This study is performed using experimental tests carried-out on a 3 kW squirrel cage induction motor. The energy evaluation of known bandwidth details allows defining a fault severity factor (FSF). This FSF is used to show which signals, wavelet type and wavelet order are more sensitive for the fault detection task. [ABSTRACT FROM AUTHOR]

This paper presents an improved method for the broken rotor bar detection in a squirrel-cage induction motor (IM). The method is based on the spectral analysis of the transient stator current signal during the counter-current braking (CCB). Contrary to the classical CCB, the proposed method results in the low braking current, which is a small fraction of the rated value and serves as a broken bar detection test signal only. This kind of the broken rotor bar fault diagnosis is independent of loading conditions and can be carried out even for a free shaft motor. The existence of spectral components in the low CCB current signal indicating the faulty conditions is first proven with the generalized theory of symmetrical components. The method is then verified via simulations, using an IM model based on the finite-element analysis and the magnetically coupled multiple circuits approach. Afterward, the experiments are performed, showing a good agreement with both the theoretical prediction and the simulation results, confirming the presence of the fault-induced components in the stator current spectra. [ABSTRACT FROM AUTHOR]

Motor current signature analysis (MCSA) is a well-proven technique for electrical and mechanical faults detection in induction motors. The appearance of stator current components or increase of magnitude of some components at characteristic frequencies indicates a motor fault condition. In this paper, we propose a new MCSA fault detector based on a matched subspace technique. The proposed detector consists of three steps. First, the influence of the fundamental supply frequency is removed from the current signal using an interference cancellation technique based on oblique projection. Then, the fault-related frequency is estimated from the interference-free signal using the maximum likelihood principle. Finally, the fault detection is performed using a generalized likelihood ratio test. Simulation and experimental results illustrate the effectiveness of the proposed approach for eccentricity fault, bearing faults, and broken rotor bars detection. [ABSTRACT FROM AUTHOR]

The aim of this paper is the broken rotor bars fault detection for a sensorless vector controlled induction motor drive. The technique of control used is based on the field-oriented control (FOC), where the fault effect in the mechanical speed is compensated in order to ensure the operation continuity of the machine. The broken rotor fault is detected through the rotor resistance estimation using extended kalman filter observer and the fast Fourier transforms for analyzing a several electrical and mechanical quantities (i.e., rotor speed, quadratic current components of control and stator phase current). The spectral analysis is effectuated only if the variation of the rotor resistance estimation is significant. An EKF observer has proven to be an excellent mathematical tool for the fault indicator in the variable speed drive. Moreover, the spectral analysis using FFT transforms can be a useful solution to ensure that the resistance variation indicates to broken rotor bars fault. The effectiveness of the sensorless control and the fault detection techniques are presented in simulation and validated in a real-time implementation using Matlab/Simulink with the real-time interface (RTI) based on dSpace 1104 board. [ABSTRACT FROM AUTHOR]

In this paper an ABC transient model of the three phase induction motor is developed that depends on self- and mutual inductance calculations based on accurate finite element analysis (FEA). This model can represent both healthy and broken bars’ conditions. The effects of that type of fault on the stator current, rotor bar currents distribution, the forces exerted on the rotor bars, the motor speed and motor torque are studied. It was observed that broken bar faults will cause fluctuations in the stator peak current and in the motor speed and torque. It was found that the asymmetry in the rotor bar currents will lead to asymmetrical distribution of the radial and tangential forces affecting the bars. The asymmetry in the tangential forces causes the fluctuations in the motor torque, while the asymmetry in the radial forces will increase the mechanical stresses on the rotor shaft.

Broken rotor bar (BRB) faults are one of the most common faults in induction motors (IM). One or more broken bars can reduce the performance and efficiency of the IM and hence waste the electrical power and decrease the reliability of the whole mechanical system. This paper proposes an effective fault diagnosis method using the Teager−Kaiser energy operator (TKEO) for BRB faults detection based on the motor current signal analysis (MCSA). The TKEO is investigated and applied to remove the main supply component of the motor current for accurate fault feature extraction, especially for an IM operating at low load with low slip. Through sensing the estimation of the instantaneous amplitude (IA) and instantaneous frequency (IF) of the motor current signal using TKEO, the fault characteristic frequencies can be enhanced and extracted for the accurate detection of BRB fault severities under different operating conditions. The proposed method has been validated by simulation and experimental studies that tested the IMs with different BRB fault severities to consider the effectiveness of the proposed method. The obtained results are compared with those obtained using the conventional envelope analysis methods and showed that the proposed method provides more accurate fault diagnosis results and can distinguish the BRB fault types and severities effectively, especially for operating conditions with low loads.

This paper presents the use of a fuzzy-based statistical feature extraction from the air gap disturbances for diagnosing broken rotor bars in large induction motors fed by line or an inverter. The method is based on the analysis of the magnetic flux density variation in a Hall Effect Sensor, installed between two stator slots of the motor. The proposed method combines a fuzzy inference system and a support vector machine technique for time-domain assessment of the magnetic flux density, in order to detect a single fault or multiple broken bars in the rotor. In this approach, it is possible to detect not only the existence of failures, but also its severity. Moreover, it is not necessary to estimate the slip of the motor, usually required by other methods and the damaged rotor detection was also evaluated for oscillating load conditions. Thus, the present approach can overcome some drawbacks of the traditional MCSA method, particularly in operational cases where false positive and false negative indications are more frequently. The efficiency of this approach has been proven using some computational simulation results and experimental tests to detect fully broken rotor bars in a 7.5 kW squirrel cage induction machine fed by line and an inverter.

Current research in broken rotor bar (BRB) fault detection in induction motors is primarily focused on a high-frequency resolution analysis of the stator current. Compared with a discrete Fourier transformation, the parametric spectrum estimation technique has a higher frequency accuracy and resolution. However, the existing detection methods based on parametric spectrum estimation cannot realize online detection, owing to the large computational cost. To improve the efficiency of BRB fault detection, a new detection method based on the min-norm algorithm and least square estimation is proposed in this paper. First, the stator current is filtered using a band-pass filter and divided into short overlapped data windows. The min-norm algorithm is then applied to determine the frequencies of the fundamental and fault characteristic components with each overlapped data window. Next, based on the frequency values obtained, a model of the fault current signal is constructed. Subsequently, a linear least squares problem solved through singular value decomposition is designed to estimate the amplitudes and phases of the related components. Finally, the proposed method is applied to a simulated current and an actual motor, the results of which indicate that, not only parametric spectrum estimation technique. [ABSTRACT FROM AUTHOR]