10 29048-Makufebed 755638-1243723
10 29048-Makufebed 755638-1243723
10 29048-Makufebed 755638-1243723
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https://doi.org/10.29048/makufebed.755638
Mehmet Akif Ersoy Üniversitesi Fen Bilimleri Enstitüsü Dergisi 11(2): 176-188 (2020)
The Journal of Graduate School of Natural and Applied Sciences of Mehmet Akif Ersoy University 11(2): 176-188 (2020)
1Burdur Mehmet Akif Ersoy University, Faculty of Engineering and Architecture, Burdur-Turkey
ABSTRACT
Induction motors are one of the most commonly used motor in the industry. For this reason, a fault (electrical or
mechanical) inside or outside of the motor can cause the motor to go out of power and even cause the production
losses inside the factory. Although there are many studies on single-cage induction motor failures in the literature,
double cage motor failures are not a frequent subject of study. Therefore, in this study, it was investigated how the
outer cage slot faults in a double cage induction motor affect the motor performance. Analyses were performed using
Finite Element Method (FEM). 1, 2, 3 and 4 outer cage broken bars in the rotor slot were investigated. Rotor currents,
magnetic vector potential values, magnetic flux distributions, current densities, radial forces and torque-speed graphs
of the motor models were obtained and compared for both healthy and failure motors. The results show that as the
number of broken bar in the rotor increased, a significant reduction was observed in all three torque (starting, maxi-
mum and nominal) values. It has been observed that the starting torque decreased by 13.77% for the 4 broken outer
cage rotor bars motor according to the healthy motor.
Keywords: Broken bars, finite element method, induction motor, outer rotor cage fault, performance analysis
Asenkron motorlar endüstride en sık kullanılan motorlardan birisidir. Bu nedenle, motorun içinde veya dışında bir
arıza (elektrik veya mekanik) motorun gücünün kesilmesine ve hatta fabrika içinde üretim kayıplarına neden olabilir.
Literatürde tek kafesli asenkron motor arızaları üzerine çok sayıda çalışma olmasına rağmen, çift kafesli motor arıza-
ları sıkça araştırılan bir konu değildir. Bu nedenle, bu çalışmada, çift kafesli bir asenkron motorun dış kafes oluğundaki
hataların motor performansını nasıl etkilediği araştırılmıştır. Analizler Sonlu Elemanlar Yöntemi (SEY) kullanılarak
yapılmıştır. Rotor oluğunda 1, 2, 3 ve 4 adet dış kafes kırığı olan motor modelleri incelenmiştir. Motor modellerinin
rotor akımları, manyetik vektör potansiyel değerleri, manyetik akı dağılımları, akım yoğunlukları, radyal kuvvetler ve
moment-hız grafikleri elde edilmiş ve hem sağlam hem de arızalı motorlar için karşılaştırılmıştır. Sonuçlar, rotordaki
kırık çubuk sayısı arttıkça, her üç moment (yol alma, maksimum ve nominal) değerinde önemli bir azalma meydana
geldiğini göstermiştir. Sağlam motora göre, rotor oluğunda 4 kırık bulunan motorun yol alma momentinin %13.77
oranında azaldığı görülmüştür.
Anahtar Kelimeler: Kırık çubuklar, sonlu elemanlar yöntemi, asenkron motor, dış rotor kafes arızası, performans
analizi
INTRODUCTION and the likes (Gyftakis et al., 2012). The double cage ro-
tor is an effective technique that improves the starting
The three phase squirrel cage induction motor is now performance of induction motors (Yamamoto et al.,
one of the most reliable, efficient and cost effective elec- 2017), which provides high starting torque and low start-
tric machines which is the largest electrical energy con- ing current (Guru et al., 2013). Double cage rotors are
sumer in the industry (Tudorache et al., 2006; Wang et characterized by the large outer (starting) bar resistance
al., 2018). Induction motors have many advantages and large inner (running) bar leakage inductance, as
thanks to their easy and robust construction. This type shown in Figure 1. The high starting torque is obtained
of machine is extensively used in many industrial appli- by confining the current to the high resistance outer cage
cations (Nakamura and Mizuno, 2013; Roubache et al., during the startup transient at high slip when the induc-
2016; Brooks et al., 2018). In general, induction motors tive impedance is dominant over the resistive imped-
are manufactured in two ways with squirrel cage and ance as shown in Figure 1 (Lorenzani et al., 2012). In
wound rotor. Although the single cage structure in the the figure, Vs is voltage, Is is stator current, Ir is rotor cur-
industry is used more and more, the double cage rotor rent, Rs is stator resistance, Xs is stator reactance, Xm is
structure has a few applications (Lorenzani et al., 2012). magnetization reactance, Rr1 and Xr1 are outer cage re-
Some of these applications can be given as follows: con- sistance and reactance, Rr2 and Xr2 are inner cage re-
veyors, crushers, mixers, compressors, loaded pumps sistance and reactance, s is slip value and Im is magnet-
ization current.
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Performance Analysis of Double Cage Induction Motor with Broken Bar Faults in Outer Cage
Figure 3. Double cage geometries in different structures (Bernatt and Bernatt, 2013; Boughrara and Ibtiouen, 2014;
Jahic et al., 2015; Preez, 2016; Yamamoto et al., 2017)
In the literature, it is seen that single cage rotor struc- whereas that of off-line standstill tests is not influenced
tures are generally used for rotor fault analysis of three for broken outer cage bars. In the Gritli et al.’ (2014) pa-
phase induction motors. These failures are usually 1, 2 per, a discrete wavelet transform-based method is pro-
or 3 broken rotor bars or end ring failures (Hamdani et posed for the detection of outer cage faults in Double
al., 2008; Xie et al., 2012; Pezzani et al., 2014; Ishikawa, Cage Induction Motors (DCIMs) operating under transi-
2015; Xie et al., 2018; Yetgin, 2019). There are publica- ent load conditions. An experimental study on a custom
tions in the form of comparison of faulty conditions and built copper double cage rotor shows that the proposed
healthy motor, and there are a limited number of publi- approach offers good diagnostic capability compared to
cations related to double cage rotor faults. the existing techniques for DCIMs used in speed-varying
applications and solves some of the previous problems.
In Boughrara and Ibtiouen (2014) studies, they have pro-
vided an analytical method for calculating the magnetic In this study, the effects of broken bars on motor perfor-
field distribution, electromagnetic performance and mance were investigated in detail by performing an anal-
equivalent circuit parameters in the case of a healthy ysis of the outer cage faults which may occur in a double
and broken rotor bar with double cage rotor induction cage induction motor. Healthy motor and 1, 2, 3 and 4
motor. Munteanu et al. (2012) used a three phase induc- outer cage broken bar motor models were analyzed with
tion motor used in the mining industry to obtain the min- FEM. Magnetic vector potential, magnetic field, flux dis-
imum current and maximum torque using a double cage tributions, inner and outer cage rotor currents, torque-
rotor slot structure. In the Daviu et al.’ (2011) paper, con- speed graphs analysis were obtained for each motor
sidering that the influence of the faulty outer cage is model. In this study, it contributes to the literature be-
strong at startup due to the large outer cage current, de- cause it investigates the effects of double layer broken
tection of outer cage faults under the startup transient is rotor bar failures on the motor instead of single layer bro-
investigated. A Discrete Wavelet Transform-based ken rotor bar failures, which is the subject of many stud-
method is proposed as a viable solution to detection of ies in the literature.
outer cage faults for double cage motors. The aim of
Gyftakis’s (2013) paper is to compare and evaluate dif- Induction Motor Faults
ferent diagnostic tools for defining broken bar failure in
delta connected double cage induction motors. The Induction motors are the most preferred electric motors
study is performed with FEM. Lorenzani et al. (2012), in the industry due to their robust construction and not
were derived and verified a dynamic model for double easy failure. However, for unexpected reasons, faults
squirrel cage rotor induction motors with outer cage that may occur inside or outside of the motor prevent the
faults. It was shown in the paper that parameter identifi- operating efficiently. There are several methods for de-
cation is a critical part of the dynamic model. This is not tecting faults that may occur in induction motors. Thanks
a trivial or straightforward procedure for double cage ma- to these methods, the motor can be deactivated without
chines, and an accurate finite element analysis can be failure.
very helpful for representing parameters accurately un-
der different operating conditions. In the Park et al.’ Detection of motor faults in the initial phase is important
(2010) paper, the detectability of broken outer cage bars because it leads to increased reliability and low failure
in double cage motors for the most commonly used rotor time. Motor failure could not be determined in the first
bar test methods is evaluated. A finite element and ex- step can lead to disaster and induction motor can be se-
perimental study show that the sensitivity of on-line mo- riously damaged (Kathir et al., 2012). Induction motor
tor current signature analysis is significantly decreased, faults are divided into electrical and mechanical faults.
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Yetgin 11(2): 176-188 (2020)
Figure 4. Healthy rotor and rotors with one, two and three broken bars (Pezzani et al., 2014)
The temperature rise around the cracked bars may Rotor faults are caused by a combination of various
eventually break the bars and the electric arc occurs stresses acting on the rotor. These stresses can be elec-
around the broken bars. This may damage the lamina- tromagnetic, thermal, residual, dynamic, environmental
tions of the rotor body close to the broken bar region. and mechanical. However, induction motor rotor faults
The following reasons can lead to cracking or breakage usually start from a small break in the rotor bar or from a
of the rotor bars (Faiz et al., 2007): high resistance point. When such a fault increases, the
magnetic field becomes increasingly asymmetrical due
Thermal stress due to over-load, non-uniform heat to the absence of induced currents in the broken rotor
distribution, hot spot and arc. bars. This leads to local saturation and disproportionate
Magnetic stresses due to electromagnetic forces, magnetic distribution in the stator and rotor teeth near
magnetic asymmetry forces, noises and electro- the broken bars. The increase of high harmonic compo-
magnetic vibrations. nents can trigger several electromagnetic events, such
Residual stress from the fabrication process. as the development of inverse magnetic field, torque
Dynamic stress due to rotor axial torque and cen- pulse, and unbalanced magnetic attraction. All these
trifugal forces. events are not desirable because they reduce the relia-
Circumferential stress due to wearing and pollution bility of the induction motor. The resistance of the broken
of rotor material by chemical materials and humid- bars is very high compared to the value of the healthy
ity. rotor bars. This is very likely to cause disproportionate
Mechanical stress due to mechanical fatigue of dif- distribution of rotor currents. The parts of rotor currents
ferent parts, ball-bearing damage, loosens lamina- that are not flowing in the broken bars due to high re-
tions etc. sistance flow in the bars next to the broken. This results
179
Performance Analysis of Double Cage Induction Motor with Broken Bar Faults in Outer Cage
in an increase in the value of these bars. Although the These regions must be enclosed by air to get accurate
broken bar currents flow in adjacent bars, the sum of the results of the torque. The electromagnetic torque is com-
rotor currents is lower than in the healthy rotor. Very high puted by a volume integration of Maxwell’s stress tensor
current density causes overheating in the bar (Vaimann over the selected area. An average valued torque (or
and Kallaste, 2011). It can cause torque and speed fluc- weighted torque) is calculated in the time-harmonic sim-
tuations, noise and unstable stator currents, reduce av- ulations. The Maxwell’s stress tensor is used to calculate
erage torque (Maouche et al., 2014). the radial air-gap forces (Fr) in Equation (2) (Wilow,
2014).
MATERIAL AND METHODS
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Yetgin 11(2): 176-188 (2020)
Figure 5. 4 outer cage broken bar motor model and mesh distribution
RESULTS AND DISCUSSION ture and the effects on the motor performance are ex-
plained. Table 1 includes the flux density at different lo-
In this section, the results of analysis of the faults of the cations of the stator and of the rotor at nominal operating
outer cage of the induction motor with double cage struc- conditions (sn = 0.05) for healthy and 4 broken motor
models.
Table 1. Average flux values in different regions for healthy and 4 broken bars motor models
Position Healthy [T] 4 broken bars [T] % Difference
Stator yoke 0.852 0.996 + 16.90140
Stator tooth 0.639 0.764 + 19.56181
Rotor yoke 0.650 0.801 + 23.23076
Rotor inner cage 0.639 0.735 + 15.02347
Rotor outer cage 0.934 0.995 + 6.531049
When the Table 1 is examined, the average magnetic maximum flux density value obtained from the healthy
flux density values of the 4 broken motors at the deter- motor is 1.68 T, while the value obtained from the 4 rotor
mined points indicate that the values of the motor have bar broken motor is 1.92 T. In order to understand the
increased significantly according to healthy motor. This difference between the magnetic flux densities given in
situation explains that 4 broken motors have saturation the figure, the lower bound value of the scale is set to
at these points according to healthy motor and have a zero and the upper bound value is set to 1.95 T. When
negative effect on motor performance. the figure is examined, it is seen that the flux density val-
ues obtained from 4 broken motor models are higher.
Figure 6 shows the magnetic flux distributions obtained This figure also shows that the obtained results which
from healthy and 4 broken motor models. The flux distri- consistent with the average flux density values in Table
butions of the healthy motor are given in Figure 6(a), and 1.
the 4 broken motor model is given in Figure 6(b). The
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Performance Analysis of Double Cage Induction Motor with Broken Bar Faults in Outer Cage
Figure 7 (a) and (b) show the current density distribution slots. It is seen that the current density values in the in-
of healthy and 4 broken motor models respectively. Cur- ner cage bars in the slots with broken rotor bars in-
rent density scale is taken the same for each model. Bro- crease.
ken rotor bars are shown as bars 3, 4, 5 and 6. The bro-
ken bars are formed only in the outer cage of the rotor
The current density values for healthy and 4 broken mo- bars. This is due to the current accumulation in the bars
tor models are given in Figure 8. There is a balanced around the broken rotor bars. In the healthy motor, more
current density in the non-broken rotor bars and current balanced current density values are obtained.
density values are seen to increase gradually in broken
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Yetgin 11(2): 176-188 (2020)
4 Broken Motor
Healthy Motor
10
6
Bar 1 Bar 2 Bar 3 Bar 4 Bar 5 Bar 6 Bar 7 Bar 8
(1 (2 (3 (4
Broken) Broken) Broken) Broken)
Figure 8. Current density graph for healthy and 4 broken bar motor (bar 1-8)
Figure 9 shows the change in average and maximum healthy motor. Average current values were obtained
current values obtained from healthy and broken motor close to each other.
models. When the figure is examined, it is seen that as
the number of broken rotor increases, there is an in-
crease in the maximum current value according to the
560
Average and Maximum Current [A]
550
540
530
Average Current
520
Maximum Current
510
500
490
480
Healthy 1 Broken 2 Broken 3 Broken 4 Broken
The change in rotor currents in each rotor slot are shown The simulated results of the rotor current magnitude for
in Figure 10. It is seen that the currents change in an each inner and outer cage bar for a faulty rotor with 4
unbalanced manner in the broken rotor parts. In the broken outer bars are shown in Figure 11. While the cur-
other parts, it is seen that the currents are obtained close rent values of the broken rotor bars are zero, it is seen
to each other. It is seen that the currents in the broken that there is a large increase in the current values in the
bars 3, 4, 5 and 6 show differences, and the flows are inner cage of the same bar.
affected by the broken structure in the slots on the right
and left sides of the broken bars. Other rotor bars have
a balanced current distribution.
183
Performance Analysis of Double Cage Induction Motor with Broken Bar Faults in Outer Cage
600
500
300
200
100
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Broken Number of Rotor Slot
Bars Healthy 1 Broken 2 Broken 3 Broken 4 Broken
500
Inner Rotor Bar Outer Rotor Bar
400
Rotor Bar Current [A]
300
200
100
4 Broken Bars
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Number of Rotor Bar
Figure 12 shows the variation of the magnetic vector po- Figure 13 presents the magnetic flux distributions in the
tential occurring in the air gap of the induction motor. In air gap obtained from healthy motor and broken motor
the section where the broken bars are deformed, the re- models. When the shape is examined, it is seen that the
sults obtained in the other parts seem to be equal. This flux density values change in the broken parts.
situation also affects the flux distribution negatively.
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Yetgin 11(2): 176-188 (2020)
The forces obtained in the radial direction is given in Fig- more force and this increases the probability of breaking
ure 14. Variations in magnetic vector potential and B val- in broken bars.
ues caused an increase in radial force values. This situ-
ation indicates that the broken areas are exposed to
185
Performance Analysis of Double Cage Induction Motor with Broken Bar Faults in Outer Cage
Figure 15 shows the torque-speed curves for each motor same way, significant differences were obtained in max-
model. It is seen that the most important difference is at imum torque values. As the number of broken rotor bar
the starting torque. It is observed that the starting torque increased, the torque values decreased. Torque values
obtained from 4 broken motor models leads to a de- obtained from healthy and broken motor models are
crease of 13.77% compared to the healthy motor. In the given in Table 2.
186
Yetgin 11(2): 176-188 (2020)
187
Performance Analysis of Double Cage Induction Motor with Broken Bar Faults in Outer Cage
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