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Master of Engineering
In
Electrical Power System
By
Praful Dewanand Thamke
Roll No. 1327
CERTIFICATE
Certified that the contents of thesis entitled “Neural Approach for Fault
Classification in Induction Motors by Using Motor Current and Voltage”
is a bonafied work carried out under my supervision by Praful Dewanand
Thamke in partial fulfillment of the requirements for the degree of Master of
Engineering in Electrical Power System.
Date: Dr.Mrs.A.U.Jawadekar
Advisor
Approved
(Dr.S.R.Paraskar) (Dr.S.B.Somani)
Head
Principal
Electrical Engg. Department
______________________________________________________________
CERTIFICATE OF APPROVAL
i
Chapter 1 Introduction
INTRODUCTION
1.1 Background
Induction motors are most widely used electrical machines in industry
because of their low cost, reasonably small size, ruggedness, low
maintenance, and operation with an easily available power supply. More than
80% of electromechanical conversion in industrial drives belongs to the
Induction Motor. Furthermore, the total number of operating electrical
machines in the world was around 16.1 billion in 2011, with a growth rate of
about 50% in the last five years [1]. Accordingly, in many industrial processes,
the induction motor plays a key role as a prime mover. Although induction
motors and specifically squirrel-cage induction motors have a rugged
structure, as with all energy conversion systems, their reliability is not
absolute. Since in many applications induction motors are the main prime
movers in such industrial processes. Sudden failure of such motor may be
very damaging or catastrophic in an industrial system, in which electrical
motor is the prime mover. Consequently, failure motors reduces the
productivity in industry. Hence the frequent maintenance schedule is very
important to prevent this failure. Generally mechanical faults, for e.g. Rotor cut
bar, stator interturn faults, bearing faults etc. may often have negligible effects
on the machine performance, however such faults may rapidly lead to
substantial interturn faults and subsequently catastrophic failures. Such failure
may cause damages the motor insulation which leads to generates heat in the
defective region which causes the fault to rapidly progress to more severe
forms, which may damage stator winding and core of the motor. Earlystage
fault detection will enable orderly process shutdown, thereby avoiding
expensive repairs and minimizing lost production time. Accordingly, it is
worthwhile to detect these faults at an early stage to prevent further damage
to the machine and involved systems [2].
Accordingly, an on-line fault diagnostic system becomes a valuable tool
to increase industrial efficiency and reliability. Thus, on-line condition
monitoring and diagnostics are becoming very important issues in electric
machine protection systems since they greatly improve reliability, availability
and maintainability in a wide range of applications.
2. LITERATURE REVIEW
2.1 Introduction
Condition monitoring is defined as the continuous evaluation of health of
the plant and equipment throughout its service life. It is important to be able to
detect the faults while they are still developing. This is called incipient failure
detection. The incipient detection of motor failure also provides a safe
operating environment. It is becoming increasingly important to use
comprehensive condition monitoring scheme for continuous assessment of
the electrical condition of the electrical machines. By using the condition
monitoring, it is possible to adequate warning of imminent failure. In addition,
it is also possible to schedule future preventive maintenance schedule.
Condition monitoring allows the machine operator to have the necessary
spare part before the machine is stripped down, thereby reducing outage
time. Therefore effective fault classification of electric machine is critical in
improving the reliability, safety and productivity.
In this chapter, the literature on fault classification is reviewed. This
review covers some important and most useful techniques such as condition
monitoring, fault classification and diagnosis, Artificial Neural Network etc. In
addition, this review also covers the major development in this field from early
research to most recent.
short circuits. The model is based on the multiplied coupled circuit approach.
The inductances calculation is performed an extension in 2- D of the modified
winding function approach (EMWFA), which was able to take into account the
space harmonics in addition to the effects of rotor bar skewing and to the
linear rise of MMF across the slots. From the results it is shown that the inter-
turn short circuit gives rise to some spectral components which appear in the
current line spectrum [5].
the circulating current increases slightly beyond the phase current level even
before the occurrence of higher levels of damaging circulating currents.
Hence, the swing angle index enables one to detect stator interturn faults at
an early stage to prevent further damage to the machine and involved
systems [2].
Nejjari and Benbouzid have used the Park‟s vector patterns for detecting
different types of supply faults, such as voltage imbalance and single phasing.
In addition a neural network based back propagation algorithm is used to
obtain the machine condition by testing the shape of the Park‟s vector
patterns. Two neural network based approach have been used, these are
classical and decentralized. The generality of the proposed methodology has
been experimentally tested and the authors claim that the results provide a
satisfactory level of accuracy [9].
Bouzid has suggested a neural network approach for the detection and
location automatically of an inter-turn short circuit fault in the stator windings
of an induction motor. In this paper they have used a feed forward multi-layer
perceptron neural network which is trained by the back propagation
technique. The phase shift between the phase voltage and line current of an
induction motor is used as the input to the neural network. The desired output
is set to either „one‟ or „zero‟. If a short circuit is detected and located on one
of the three phases, the corresponding neural network output is set to „one‟;
otherwise, it is „zero‟ [10].
3 INDUCTION MOTOR
3.1 Introduction
An induction motor comprises a magnetic circuit interlinking two electric
circuits which are placed on the two main parts of the machine:
(i) The stationary part called the stator and
(ii) The rotating part called the rotor.
Power is transferred from one part to the other by electromagnetic
induction. For this induction machine is referred as an electromechanical
energy conversion device which converts electrical energy into mechanical
energy. Rotor is supported on bearings at each end.
Generally, both the stator and rotor consist of two circuits: (a) an
electric circuit to carry current and normally made of insulated copper or
insulated aluminium and (b) a magnetic circuit, shown in Figure 3.1, to carry
the magnetic flux made of laminated magnetic material normally steel. The
different components of an induction motor are shown in figure 3.2.
3.2 Construction
A 3-phase induction motor has two main parts (I) stator and (II) rotor.
The rotor is separated from the stator by a small air-gap which ranges from
0.4 mm to 4mm, depending on the power of the motor
3.2.1 Stator
It consists of a steel frame which encloses a hollow, cylindrical core
made up of thin laminations of silicon steel to reduce hysteresis and eddy
current losses. A number of evenly spaced slots are provided on the inner
periphery of the laminations shows in figure 3.4. When 3-phase supply is
given to the stator winding, a rotating magnetic field of constant magnitude is
produced.
3.2.2 Rotor
The rotor mounted on a shaft is a hollow laminated core having slots
on its outer periphery. The winding placed in these slots (called rotor winding)
may be one of the following two types.
2 Wound type
It consists of a laminated cylindrical core and carries a 3 phase
winding, similar to the one on the stator shows in figure 3.6 the rotor winding
is uniformly distributed in the slots and is usually star- connected. The open
ends of the rotor winding are brought out and joined to three insulated slip
rings mounted on the rotor shaft with one brush resting on each slip ring.
Besides the above two main parts, an induction motor consists some
other parts which are named as follows:
(i) End flanges: There are two end flanges which are used to support
the two bearings on both the ends of the motor.
(ii) Bearings: There are two set of bearings which are placed at both
the ends of the rotor and are used to support the rotating shaft.
(iii) Shaft: It is made of steel and is used to transmit generated torque
to the load.
(iv) Cooling fan: It is normally located at the opposite end of the load
side, called non-driving end of the motor, for forced cooling of the
both stator and rotor.
(v) Terminal box: It is on top or either side of the outer cylindrical
frame of stator to receive the external electrical connections.
3.3 Operation
As one can observe from this table, bearing and winding related
failures are the dominant trouble areas. Moreover, the percentage of winding
related and rotor related failures are around 40 percent. This dissertation is
specifically dealing with only these two electrical types of component failure,
namely broken bar and inter-turn faults.
The majority of electric machine component failures can be related to
the three main components of the machine: the stator, the rotor, and the
bearings. Since these components account for over 80 percent of all electric
machine failures, most condition monitoring schemes have concentrated on
detecting faults in one of the three components. Again, this dissertation is
dealing with two types of stator and rotor faults mainly inter-turn shorts in
stator windings and broken bar faults in squirrel-cages motor.
Stator faults may be divided into two types these are as follows
1. Stator winding related faults
2. Stator core related faults
One of the weakest components in an electric machine, both
mechanically and electrically, is the winding insulation. Stator faults are
caused by partial stator winding insulation failures shown in figure3.7.
length between a motor and its drive, ambient stresses, and aging of the
stator winding insulation [3, 4]. Inter-turn faults lead to generated heat in the
defective region of a winding which causes the fault to rapidly progress to
more severe forms such as phase-to-phase and phase-to-ground faults.
Within humans there are many variations on basic type of neuron, yet,
all biological neurons have the same four basic components. They are known
by their biological names – cell body (soma), dendrites, axon, and synapses.
Cell body (Soma): The body of neuron cell contains the nucleus and
carries out biochemical transformation necessary to the life of neurons.
Dendrite: Each neuron has fine, hair like tubular structures (extensions)
around it. They branch out into tree around the cell body. They accept
incoming signals.
Axon: It is a long, thin, tubular structure which works like a transmission
line.
Synapse: Neurons are connected to one another in complex spatial
arrangement. When axon reaches its final destination it branches again
called as terminal arborization. At the end of axon are highly complex and
specialized structures called synapses. Connection between two neurons
takes place at these synapses.
Dendrites receive the input through the synapses of other neurons. The
soma processes these incoming signals over time and converts that
processed value into an output, which is sent out to other neurons through the
axon and the synapses.
Figure 4.2 shows various inputs to the network are represented by the
mathematical symbol, x(n). Each of these inputs is multiplied by a connection
weight. The weights are represented by w(n). In the simplest case, these
products are summed, fed to a transfer function (activation function) to
generate a result, and this result is sent as output. This is also possible with
other network structures, which utilize different summing functions as well as
different transfer functions.
Some applications like recognition of text, identification of speech,
image deciphering of scenes etc. require binary answers. These applications
may utilize the 77 binary properties of ORing and ANDing of inputs along with
summing operations. Such functions can be built into the summation and
transfer functions of a network.
Seven major components make up an artificial neuron. These
components are valid whether the neuron is used for input, output, or is in the
hidden layers.
The summation function can be more complex than just weight sum of
products. The input and weighting coefficients can be combined in many
different ways before passing on to the transfer function. In addition to
summing, the summation function can select the minimum, maximum,
majority, product or several normalizing algorithms. The specific algorithm for
combining neural inputs is determined by the chosen network architecture and
paradigm. Some summation functions have an additional „activation function‟
applied to the result before it is passed on to the transfer function for the
purpose of allowing the summation output to vary with respect to time.
bound. This limiting is in addition to the hard limits that the original transfer
function may have performed.
Figure 4.3 shows an artificial neural network. Inputs enter into the
processing element from the upper left. The first step is to multiply each of
these inputs by their respective weighting factor [w(n)]. These modified inputs
are then fed into the summing function, which usually sums these products;
however, many different types of operations can be selected. These
operations can produce a number of different values, which are then
propagated forward; values such as the average, the largest, the smallest, the
OR values, the AND values, etc. Other types of summing functions can also
be created and sometimes they may be further complicated by the addition of
an activation function which enables the summing function to operate in a
time sensitive way.
The output of the summing function is then sent into a transfer function,
which turns this number into a real output (a 0 or a 1, -1 or +1 or some other
number) via some algorithm. The transfer function can also scale the output
or control its value via thresholds. This output is then sent to other processing
elements or an outside connection, as dictated by the structure of the
network.
back to its own input. Sometimes, feedback loops involve the use of unit delay
elements, which results in nonlinear dynamic behavior, assuming that neural
network contains nonlinear units.
this finalized network is then turned into hardware so that it can be fast. Other
systems don't lock themselves in but continue to learn while in production use.
rate :
This is the formula used in batch learning mode, where new weights
are computed after presenting all training samples. One such pass through all
samples is called an epoch. Before the first epoch, weights are initialized,
typically to small random numbers. A variant is incremental learning, where
weights are changed after presentation of individual training samples:
∑ ⌋
is the internal state (or potential) of unit . This is the error backpropagation
pass. Mathematically, the error propagation term represents the error
gradient with respect to the potential of the unit .
After every such epoch, compute the error. Stop when the error falls
below a predetermined threshold or when the change in error falls below
another predetermined threshold or when the number of epochs exceeds a
predetermined maximal number of epochs. Many (order of thousands in
nontrivial tasks) such epochs may be required until a sufficiently small error is
5 SPACE VECTOR
5.1 Introduction
Space vector is a transformation for analyzing three-phase electric
systems. The term “space” originally stands for the two-dimensional complex
plane, in which the three-phase quantities are transformed. In electric
machines it is combined with the magnetic field [13]. In order to understand
the concept of space vector, it is helpful to start from observing the structure
of an electric machine that is driven by a three-phase current.
An electric machine is usually composed of a stator and a rotor.
Usually a stator is the outer part of the machine with windings, which are
connected to the three-phase grid to generate a rotating magnetic field.
Different rotors are available in different types of machines. However,
the structure of the stator is almost the same. In a three phase machine with
one pole pair, three copper windings are embedded in the slots of the stator
iron structure. Figure 5.1 shows one distributed winding of the stator with a
simplified drawing.
circumstance. For a three phase machine with one pole pair, the simplified
winding structure is shown in figure 5.2
Three windings are organized with 120° angle difference in the physical
space between each other. On the right side of the figure they are illustrated
in a simplified way, where a winding is represented with an inductor.
The arrowed lines attached to the windings define the directions of the
currents in the windings in a form of vector. The three current currents are
named as ia, ib and ic. The vector magnitudes are equal to the current
magnitudes, respectively.
It must be noticed that the vector directions are not the directions of the
physical currents flowing in the windings. The vectors defined with directions
are only used for analysis.
At a certain time point, e.g., the currents in the three windings have the
directions and values as shown in Figure 4.3; they could be summarized
together using vector addition. The result is ia, ib and ic as shown in the figure
5.3.
5.2 Definition
Referring to Figure 5.3, the sum of the current vectors as
Isum= + + = + + (1)
√ √
I sum= (2)
Where, and =
And ⃗s is the magnitude and θ is the angle of the space vector. Instead
of the coefficient, 2/3, other coefficients could also be used, e.g.√ , for
6. METHODOLOGY
6.1 Introduction
When the induction motor is in the faulty condition such as if the motor
rotor bar get damage or inter-turn short circuit occurring in one or more
phases in the winding then such types of induction motor is represented as an
unsymmetrical three phase system. The analysis of such system can be
achieved by using symmetrical component or space vector form namely
positive, negative and zero sequence components. In this chapter, different
techniques have been exploited with the help of space vector form of stator
phase voltage and current to classify the rotor broken bar fault and stator
inter-turn short circuit fault. These techniques have gained popularity over
other techniques due to their generalization capability, which means that they
are able to perform satisfactorily even for unseen fault.
In this dissertation three types of techniques were used to classify the
different types of faults occurred in the induction motor which are based on
the space vector form of stator current and voltage signal. These are:
1. Fault classification using Pendulous oscillation.
2. Fault classification by using Negative Sequence current and swing
angle.
3. Fault classification by using Artificial neural network
And va(t), vb(t), vc(t) and ia(t), ib(t), ic(t) are phase voltages and phase
current of phase a, b, c respectively. After defining the space vector of stator
voltage and current, the angular phase shift called swing angle and the
absolute value of the real part of the space vector of the stator current at any
point (r, δ) in the polar plot is determined by following expression.
Similarly the swing angle is the peak to peak value of δ is known as swing
angle ‘ and it is expressed as
Machine failure disturbs the air gap magnetic fields which is oscillates
around its originally synchronous axis. This oscillation can be defined by
measuring the phase displacement between the stator voltage and current
which is denoted by δ. The peak to peak values of δ is known as swing angle
express in (5).
The number of neurons in the input and output layers is governed by the
number of inputs and outputs of the pattern to be recognized. However, the
number of neurons in the middle layer can be selected depending upon the
applications. Input patterns are exposed to the network whose output is
compared with the target values to calculate the error which is corrected in the
next pass by adjusting the synaptic weights to get desired output.
1. Induction Motor
The experimental set up is developed by reconfiguring of an existing
induction motor rated at 2-hp. It has 24 coils, 36 slots in all. Each phase
comprises 8 coils carries 300 turns. A phase has been tapped where each
tapping is made after 10 turns, near to the star point (neutral).
In order to emulate stator inter-turn short-circuit faults, the motor has a
phase winding that was prepared with taps for the purpose of “experimental
mimicking” of incipient inter-turn faults. Therefore one of the three phases has
been tapped where each tapping is made after every 10 turns near to the star
point (neutral).The tapings are drawn from the coils where each group
comprises of approximately 70 to 80 turns. The arrangement for tapings is
shown in figure 7.3.
2. D.C. Generator
3. Current Transformer
A CT is an instrument transformer in which the secondary current is
substantially proportional to primary current and differs in phase from it by
ideally zero degree. The secondary AC is commonly used in two ways:
To measure the size of the current in the primary circuit
To supply electronic equipment this would otherwise be damaged by
very large currents
Current transformers allow delicate equipment to be protected from
significant currents while simultaneously allowing these pieces of equipment
to be powered by those currents. This happens because current transformers
produce a secondary current via electrical induction.
To capture the motor current, Fluke i-5s current transformer known as
current clamper were used shown in Figure 7.4. The specification of fluke i-5s
current clamper is shown Table 7.4.
4. Potential Transformer
A voltage transformer or potential transformer is just like a general
purpose step down transformer shown in figure 7.5. Primary of this
transformer is connected across the phase and ground. Just like the
transformer used for stepping down purpose, potential transformer i.e. PT has
lower turns winding at its secondary. The system voltage is applied across the
terminals of primary winding of that transformer, and then proportionate
secondary voltage appears across the secondary terminals of the PT.
In this experimental setup, 230v/6v, 200mA potential transformer was
used for capturing the phase voltage of an induction motor.
.
The USB-1902 Series of 16-bit can import maximum input samples of
250 kS/s. The series also delivers 2-CH, 16-bit analog output capable of up to
1 MS/s update and programmable function I/O. The software programmable
function I/O supports a variety of functions including TTL digital I/O, general-
purpose timer/counter, and PWM output. The USB-1902Series’ analog input,
analog output, and function I/O are capable of functioning simultaneously at
full speed. The data is captured with the help of ADLINK DAQ compatible with
MATLAB. The ADLINK DAQ has 10 input ports and 10 output ports. Each port
has maximum voltage rating of 10 volts.
Figure 7.8: voltage and current signal under broken rotor bar condition.
(v) Short circuit between winding conductors and the stator core called coil
to ground fault,
(vi) Open-circuit fault when winding gets break.
Different types of stator winding faults are shown in Figure 7.9. Short-
circuit winding fault shows up when total or a partial of the stator windings get
shorted. Open-circuit fault shows up when total or a partial of the stator
windings get disconnected and no current flows in that phase/line
Figure 7.10: voltage and current signal under stator inter-turn short
circuit condition.
In this way, experimentally, the induction motor phase voltage and
current are captured under healthy, broken rotor bar and stator inter-turn short
circuit condition at full load.
As seen from figure 7.7, 7.8 and 7.10, it may observed that the
variation in voltage signal for healthy, rotor broken bar and rotor short circuit
condition is negligible small but in the current signal, there is a variation for
healthy, broken rotor bar and stator inter-turn short circuit condition.
These captured signals of induction motor stator phase voltage and
current then further used for fault classification purpose.
In healthy condition, the phase shift between the terminal voltage and current
is very small nearly unity. Therefore, the polar plot of (r, δ) is a straight line.
Here, for any angle r and δ quantities changing from zero to its maximum
values [1]. Therefore, in this case, polar plot of (r,δ) has a filled petal shape
loading conditions. So the air gap magnetic field gets oscillated due to the
short circuited winding only. So that the air gap magnetic field can be resolved
into two components in which rotate at the synchronous speed but in opposite
direction. And also, the resultant magnetic field can be resolved into a main
rotation at synchronous speed and an oscillation around the main rotation,
where the speed of this oscillation is twice the synchronous speed [1]. The
speed of the variation of r and δ quantities is same so that at any angle of δ,
the r quantity will not changes from zero to its maximum values because r and
δ are varying with time simultaneously at the same rate. Therefore in this
case, the polar plot of (r, δ) has unfilled petal shape in other word constitutes
only the outer boundary of the petal shape. Figure 8.3 shows the experimental
result of polar plot at full-load for 20-turn short circuit condition.
In this method, the peak swing angle and peak values of negative
sequence current both obtained for each cycle were used. The swing angle,
Δδ, is obtained by calculating the maximum spread of Δδ = δmax − δmin in a
polar plot diagram. Thus, for each power cycle, a single value for the swing
angle, Δδ, is obtained. The results of a peak values calculated swing angle for
different condition in an Induction motor are shown in Figure 8.4, 8.5 and 8.6
for healthy, broken rotor bar and stator inter-turn short circuit condition
respectively and figure 8.7 shows the comparative plots for healthy, rotor
broken bar and stator inter-turn short circuit condition.
Similarly, at the same conditions, the peak values of an on-line trace of the
negative sequence component of the line currents, which were obtained for
each cycle, for different condition in an Induction motor are shown in Figure
8.8, 8.9 and 8.10. And by comparing all the plots the classification is done
shown in figure 8.11
Hear the classification of healthy condition and broken rotor bar is quite
difficult with swing angle curve method because of the closeness or
“bunching-up” nature of the traces. This is because of the fact that the
rewound 2-hp motor had an inherent manufacturing degree of unbalance due
to the manufacturing (or construction) imperfection resulting from the random
winding installation process and the layout of the winding taps. But with the
help of peak values of Negative sequence current, there are no difficulties to
classify the different types of condition. So that for the classification purpose,
by using peak value of Negative sequence current per cycle has better
accuracy than swing angle curve.
9.1 Conclusion
The common types of faults in induction motor are studied and various types
of current based condition monitoring and fault detection techniques are
reviewed. A robust and intelligent fault detection and classification of three-
phase induction motor based on pendulous oscillation concept and by using
Artificial Neural network has been introduced and examined with the 2-hp,
three phase Induction motor. The experimental results showed the strength
and fidelity of this method, even in the presence of a degree of machine
construction imperfections. The pendulous oscillation techniques gives the
accurate classification of healthy, rotor broken bar and stator interturn short
circuit condition of motor which shown that the negative sequence of stator
current is the responsible one to detect rotor broken bar fault and stator
interturn faults of machine which further used in ANN for classification
purpose. And also observed that Feed-forward ANN with the supervised
learning algorithm and Tansigmoid transfer function and with three processing
elements in the hidden layer is the best network to classify multiple faults in
an induction motor with 100% accuracy.
identify the faults at all three symmetrical winding motors such as three phase
synchronous motor and also three phase generator.
These techniques can also be extended for identification of synchronism
test in generator with the grid supply.
Neural network ensembles are receiving increasing attention in the
field of research such as control, fault diagnosis, decision making,
identification, robotics etc. due to their learning and generalization abilities,
nonlinear mapping, and parallelism of computation. However, for solving fault
detection problems the neural networks may get stuck on a local minimum of
the error surface, and the network convergence rate is generally slow. A
suitable approach for overcoming these disadvantages is the use of wavelet
functions in the network structure. Wavelet function is a waveform that has
limited duration and an average value of zero. A wavelet neural network has a
nonlinear regression structure that uses localized basis functions in the
hidden layer to achieve the input-output mapping.
The integration of the localization properties of wavelets and the learning
abilities of neural network results in the advantages of wavelet neural network
over neural network for the detection and location of an inter-turn short circuit
fault in the stator winding of an induction motor.
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