| Summary: | Electric motors play a pivotal role in various industrial plant processes for
electrical to mechanical energy conversion. As a result their reliability and
availability is of utmost importance to industries. The reliability and availability of
plant electric motors can be achieved by early detection of any developing fault
by performing condition monitoring and preventative maintenance on motors.
An important motor failure mode, which has been quite challenging to detect, is
cracking and subsequent breaking of rotor bars in induction motors.
The existing condition monitoring techniques are incapable of positively detecting
a cracked or single bar problem during operating conditions. Bars have broken,
lifting out of the rotor slots and damaging all stator coils, consequently forcing the
removal of the motor during plant operation and a complete rewind of the stator.
This research is being conducted to ascertain, from existing conventional
techniques, an optimal technique for the detection of a cracked rotor bar or a
completely broken single rotor bar in induction motors under operating
conditions. Furthermore, it explores non-conventional techniques, which can
assist in detection of broken rotor bars.
The report starts by presenting the literature on stator current and axial vibration
analysis which are conventional rotor bat detection techniques. Thereafter, the
Maxwell 2D simulation results which indicate stator current broken rotor bar
detection frequencies are discussed, followed by the experimental measurement
results and discussions. The conclusion drawn from the experimental results is
that the stator current analysis is, presently, the optimal technique to detect a
single broken rotor bar during a medium voltage induction motor operation. The
axial vibration analysis is recommended as a secondary monitoring technique to
solidify the stator current diagnosis. The shaft voltage analysis is introduced as a
non-conventional technique and the shaft voltage results are discussed.
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