Predictive Maintenance Practices of Induction Motor: V Venkatesh, D Vamsi Krishna, KV Kalyani, D K Panda
Predictive Maintenance Practices of Induction Motor: V Venkatesh, D Vamsi Krishna, KV Kalyani, D K Panda
Predictive Maintenance Practices of Induction Motor: V Venkatesh, D Vamsi Krishna, KV Kalyani, D K Panda
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Submitted: 05-08-2022 Revised: 11-08-2022 Accepted: 15-08-2022
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ABSTRACT reduce the downtime in handling faults and to
This paper proposes various approaches for the increase the efficiency/reliability of motors. In this
predictive maintenance of motors. Manufacturing context predictive maintenance performs an
industries spent a huge amount of money on important role to achieve reliability in the process.
rotating equipment. To keep the machine capable Since the Induction motor shares a vast majority in
of performing the desired task without breakdown, industrial applications, conditional analysis is to be
regular maintenance is to be practiced. Predictive followed on various parts of the motor to improve
maintenance is an essential technique to predict its efficiency. Conditional monitoring avoids
possible shortcomings in the early stage. The unplanned downtime by detecting and diagnosing
electrical signature analysis technique is a precise impending machine failures. This not only helps
analysis technique which is performed by using plant personals from reducing the catastrophic
current and voltage signatures from the motor failure but also allows companies to order parts in
feeder. It predicts possible fault occurrence in advance, schedule personnel and plan other repairs
different parts of the motor. Vibration analysis during the downtime. Various conditional
using acoustic monitoring devices deals to solve monitoring methods of predictive maintenance of
problem identification in motor positioning, soft Induction motor based on electrical and mechanical
foot case. Crucial power parameters like parameters along with the latest technologies are
harmonics, swells, transients, efficiency, etc. can explained in this paper.
easily be understood using the latest power and [1]. Predictive maintenance by Electrical Signature
motor analyzer. Computers are connected with analysis to Induction motor. Research gate
machines to take decisions without human October, 2012 Eric Leonardo Bonaldi, Levy ely
intervention in Industry 4.0 which improves asset de lecarda de Olivera, Jonas Guedes Borges da
life, ease of operation, and monitoring the Silva, Germano Lambert-Torresm and Luiz
equipment at a remote location is possible. Eduardo Borges da SilvaThis paper portrays
Predictive maintenance approaches using IOT various predictive maintenance methods by using
technology are explained. signature analysis techniques. Here current, voltage
KEYWORDS: Induction motor, Predictive signal is considered as a frequency signature
maintenance methods, mechanical & mechanical spectrum. The signature spectrum is transferred to
faults, Electrical signature analysis, Partial a spectrum analyzer after passing through a signal
discharge, IOT conditioner which removes irregular frequencies.
Fast Fourier Transfer tool is used in analyzing the
I. INTRODUCTION spectrum. After analyzing the obtained spectrum
Electric motor is an important rotating various possibilities of faults in the motor are
power source in the industry. Among which obtained.
Induction motor represent almost 90% of electrical [2]. Detection of Induction Motor Coupling
motors in production process. In its total life, a Unbalance and Misalignment via Advanced
motor goes through many faults, which effects the Transient Current Signature Analysis Universitat
output efficiency and performance of the plant. The Politècnica de Valencia, Research gate September
significance of predictive maintenance is to obtain 2018, JA Antonio-Daviu, Peter Popaleny. This
knowledge about the operating conditions of paper analyzes mechanical faults in an induction
equipment and to predict the possible fault. motor. Bearing failures, shaft misalignment, and
Industries are always working on newer tech incorrect assembly type mechanical problems are
DOI: 10.35629/5252-0408599607 Impact Factor value 7.429 | ISO 9001: 2008 Certified Journal Page 599
International Journal of Advances in Engineering and Management (IJAEM)
Volume 4, Issue 8 Aug. 2022, pp: 599-607 www.ijaem.net ISSN: 2395-5252
assessed using vibration and thermography paper explains the continuous monitoring of partial
techniques. The author had conducted experiments discharge activity using different PD sensors.
on a test bench with 1.1 kW 4 pole induction motor Sensors like High voltage coupling capacitor
coupled with a DC machine enabled to set different (HVCC), High-frequency current transformer
load conditions for fault analysis. The experimental (HFCT), Transient earth voltage (TEV), and
results are showcased in graphs differentiating Rogowski coil are explained. Partial discharge
healthy motor and faulty motor. activity is a key technique in conditional
monitoring of HV motor. It provides actual data
[3]. Fluke 438-II Motor and Power analyzer related to the insulation condition of the motor.
displays various electrical and mechanical From the obtained data the condition of the motor
measuring parameters without any sensors and can be assessed without interrupting the running of
transducers. The handheld instrument can measure the machine. A shutdown or other preventive
different parameters of motor drive in a loaded actions can be planned which helps the plant from
condition. The obtained parameters are displayed unplanned breakdowns.
as bar graphs for ease of understanding.
[4]. Acoustic monitoring and background noise in II. PREDICTIVE MAINTENANCE
industrial environment, Research Gate Conference METHODS OF INDUCTION MOTOR
paper June 2013, 286273695, Maciej Orman and Like all the rotating machines induction
Cajetan T. Pinto. This paper showcases motors are exposed to many different electrical,
monitoring and predictive maintenance technique mechanical, thermal, and environmental stress
for induction motors using acoustic technology. By which require thorough attention to make the
analyzing the sound emitted from the motor, faults machine work efficiently.
can be predicted. In an experimental study, the The most common electrical predictive
author used an acoustic microphone and camera for maintenance methods applied to detect faults in an
analyzing the sound of a healthy motor and a faulty induction motor are Electrical signature analysis
motor. Motor foot case arrangement had been (ESA), partial discharge detection, Motor current
altered to vary the fault level of the motor. signature analysis (MCSA), Extended park’s vector
Graphical representation differentiates the approach (EPVA), and Instantaneous power
amplitude, and frequency variation of both motors. signature analysis (IPSA). Similarly, mechanical
[5]. Predictive maintenance using IOT: IOT based predictive methods are vibration analysis, acoustic
predictive maintenance techniques enables the user analysis, and speed oscillations. By applying the
to maintain, monitor, optimize, and utilize the right maintenance practices, the service life of
assets in an effective approach. The real-time equipment, plant productivity and efficiency can be
monitoring feature allows better visibility of assets increased. The above-mentioned analysis is
and predict possible faults, identify faulty performed as predictive maintenance methods of
components, and track maintenance schedule. The induction motor.
latest IOT-enabled applications are explained in
this paper. III. FAILURES IN INDUCTION
[6]. IR Thermography technology does thermal MOTOR
information analysis from non-contact thermal Any rotating part of the motor like
imaging devices. The emitted radiation in the bearing, shaft, and rotor is most frequently prone to
infrared range of the electromagnetic spectrum is failure. Along with the rotating part, stator is also
detected. Heat development on the surface or any affected through faults due to overheating and other
part of the motor is one of the symptoms of the possible reasons. The figure shows the layout of
occurrence of a fault. Possible reasons for the induction motor with its input obtained from
progress of heat in equipment are, bearing fault, electric supply and output delivered to a
shot circuited winding, stator, rotor alignment mechanical load. During this transaction many
problems, etc. As a predictive maintenance activity, losses occur which are explained below:
all such problems can be analyzed from the thermal
condition on the equipment surface. Nowadays IR
cameras are mounted on drones for thermography
measurement of motors or loads installed away
from plants.
[7]. Detection of Partial Discharge Activity in H.V
Rotating Equipment, IJSRSET, Volume-3, Issue-1,
ISSN: 2394-4099, 2017, Hitesh B. Renuka. This
DOI: 10.35629/5252-0408599607 Impact Factor value 7.429 | ISO 9001: 2008 Certified Journal Page 600
International Journal of Advances in Engineering and Management (IJAEM)
Volume 4, Issue 8 Aug. 2022, pp: 599-607 www.ijaem.net ISSN: 2395-5252
DOI: 10.35629/5252-0408599607 Impact Factor value 7.429 | ISO 9001: 2008 Certified Journal Page 601
International Journal of Advances in Engineering and Management (IJAEM)
Volume 4, Issue 8 Aug. 2022, pp: 599-607 www.ijaem.net ISSN: 2395-5252
DOI: 10.35629/5252-0408599607 Impact Factor value 7.429 | ISO 9001: 2008 Certified Journal Page 602
International Journal of Advances in Engineering and Management (IJAEM)
Volume 4, Issue 8 Aug. 2022, pp: 599-607 www.ijaem.net ISSN: 2395-5252
DOI: 10.35629/5252-0408599607 Impact Factor value 7.429 | ISO 9001: 2008 Certified Journal Page 603
International Journal of Advances in Engineering and Management (IJAEM)
Volume 4, Issue 8 Aug. 2022, pp: 599-607 www.ijaem.net ISSN: 2395-5252
Figure 9(B): Acoustic spectrum of motor with Figure 10: HFCT sensor schematic diagram
static eccentricity and soft foot case
HVCC sensor is designed for testing and
4.4 Partial Discharge Detection using sensors. monitoring PD. The sensors are installed
permanently on each phase of the machine MCC
DOI: 10.35629/5252-0408599607 Impact Factor value 7.429 | ISO 9001: 2008 Certified Journal Page 604
International Journal of Advances in Engineering and Management (IJAEM)
Volume 4, Issue 8 Aug. 2022, pp: 599-607 www.ijaem.net ISSN: 2395-5252
DOI: 10.35629/5252-0408599607 Impact Factor value 7.429 | ISO 9001: 2008 Certified Journal Page 605
International Journal of Advances in Engineering and Management (IJAEM)
Volume 4, Issue 8 Aug. 2022, pp: 599-607 www.ijaem.net ISSN: 2395-5252
V. CONCLUSION
This paper concludes with various
predictive maintenance techniques for conditional
monitoring of induction motors in industries. The
objective of the context is to disseminate important
concepts of maintenance to guide industrial users to
have their predictive maintenance group or want to
hire external specialized consultants which deliver
Figure 13: Thermography imager good results through predictive maintenance
practices. Latest technological advances like IOT,
thermal cameras, etc. are explained here and are to
be utilized for efficient conditional monitoring of
machines.
DOI: 10.35629/5252-0408599607 Impact Factor value 7.429 | ISO 9001: 2008 Certified Journal Page 606
International Journal of Advances in Engineering and Management (IJAEM)
Volume 4, Issue 8 Aug. 2022, pp: 599-607 www.ijaem.net ISSN: 2395-5252
REFERENCES
[1]. Eric Leonardo Bonaldi, Levy ely de
lecarda de Olivera, Jonas Guedes Borges
da Silva, Germano Lambert-Torresm and
Luiz Eduardo Borges da Silva- Predictive
maintenance by Electrical Signature analysis
to Induction motor. Research gate October,
2012.
[2]. JA Antonio-Daviu, Peter Popaleny-
Detection of Induction Motor Coupling
Unbalance and Misalignment via Advanced
Transient Current Signature Analysis,
UniversitatPolitècnica de València. Research
Gate September 2018.
[3]. Fluke 438-II Motor and Power analyzer
operational manual
[4]. Maciej Orman and Cajetan T. Pinto
Acoustic monitoring and background noise
in industrial environment, Research Gate
Conference paper June 2013, 286273695
[5]. “SIMOTICS CONNECT 400” Technical
data sheet.
[6]. Fluke Thermal Imagers datasheet
[7]. Hitesh B. Renuka, Detection of Partial
Discharge Activity in H.V Rotating
Equipment, IJSRSET, Volume-3,Issue-
1,Online ISSN:2394-4099, 2017
DOI: 10.35629/5252-0408599607 Impact Factor value 7.429 | ISO 9001: 2008 Certified Journal Page 607