REVIEW OF FUNDAMENTAL

TWO POLE INDUCTION MOTOR MECHANICS

by
Cletus A. Corey
Louis Allis-Division of Magnetek

Milwaukee, Wisconsin

but immediately becomes rough when load is applied, leaving

Cletus A. Corey is the Chief Mechani­ the impression that a severe electrical problem is present. An
cal Engineer for the Large Machinery actual case was experienced with a 600 hp two pole motor
Division of Louis Allis-Division of Mag­ where the idle operation produced velocities of 0.05 in per
neTek with over 15 years of experience in second (ips) at the bearing housing, but the loaded condition
heavy capital equipment and induction resulted in a strong beat with peaks in excess of 0.4 ips. Such
motor design, analysis andfield support. cases of low idle vibration are quite common and must be
He has specialized in structural design sorted through in two pole motor diagnoses. Fundamental
dealing with modal and vibration analy­ reviews of the mechanics of both the electrical and mechanical
sis aspects of factory and field problems forces are required to understand such occurrences of two pole
involving large two pole and high horse­ problems.
power motors of up to 6000 horsepower. Dealing with two pole motor vibration problems requires -
He earned a B.S. degree in Mechanical Engineering from an understanding of the forces generated by the normal me­
Purdue University, and an M.S. degree in Engineering chanical and electrical systems within such units. In this way,
Mechanics from the University of Wisconsin-Milwaukee. He is possible sources of the abnormal forces can be separated from
a member of ASME and the Vibration Institute. the normal ones in terms of frequency or magnitude and
identified as electrical or mechanical in origin. A motor has the
normal rotating unbalance and associated mechanical forces
present, along with substantial electromagnetic radial forces,
ABSTRACT
which are components of the applied torque forces. Mechanical
An introduction to two pole motor mechanics is pre­ unbalance and the associated harmonics in an induction motor
sented, with the goal of promoting an understanding of normal follow normal rotating machine dynamics experienced in other
and abnormal vibration sources to assist in the diagnosis of the machines. Electromagnetic forces generated in motors are a bit
field problems of such motors. Motor force vectors are re­ foreign to most mechanical engineers and technicians and a
viewed, which define sample frequencies and magnitudes for review of the fundamental aspects of their sources can be most
the normal mechanical and electrical causes. Tables of sources helpful in dealing with field problems.
of both normal and abnormal forces are presented which enable Torque is generated in an induction motor by a relative
the reader to calculate the frequencies involved and possible "slipping" condition between the rotating electromagnetic field
causes for excessive levels. Sum and difference frequencies and the rotor cage. It is this slipping relationship which induces
(beat) are complicating factors in such motors and a brief a counter electromagnetic field in the rotor to drive the
nonmathematical discussion of such processes is presented, in resisting driven machine load. This process results in a pair of
terms of two pole motor vectors. A case problem is presented, electrical forces at the magnetic poles rotating at 60 Hz and a
showing an example of two pole motor beat frequencies and mechanical unbalance force rotating at a slightly lower speed.
the associated sidebands in such problem cases. The amount of slip is determined by both the electrical design
and the applied load and it is quite low in the idle operating
INTRODUCTION condition. A basic task in vibration analysis of two pole motors
Field vibration analysis of two pole 3600 cpm motors is a is to identify the magnitude and frequency of these forces and
relatively complex problem which most mechanical engineer­ how they are summed in the motor.
ing personnel are not well equipped to handle. Such motors Two pole motors are discussed here in terms of 60 Hz
have a strong load sensitivity and can run very smoothly in the power supplies and all frequencies are based on such systems.
idle condition, leading to difficulty in separating mechanical The principles are, however, identical for 50 Hz system
and electrical problems. The cause for the complexity in such motors, differing only in terms of frequency and slightly lower
analysis is a failure to define the basic force vectors in such centrifugal loads. Basic vibration analysis should follow the
motors and deal with them in terms of electrical and mechani­ same procedures and tests.
cal sources. Additional complications arise from the extreme
nonlinearity in the forces generated, leading to some very MECHANICAL FORCES
excessive sum and difference frequencies, or beat. To deal with
Unbalance in two pole motors is typical of all rotating
such motor problems more effectively, a fundamental review of
machinery and must conform to a balance standard such as
such two pole motor forces is most helpful.
International Standard Organization (ISO) 1940 Grade G2.3
(0.0005 in radius of gyration), or less, depending on whether it
FUNDAMENTAL FORCES is f lexible or stiff shaft design. A flexible shaft is one which
Two pole motors are complicated machines to deal with in operates above the first critical, while a stiff shaft is one which
terms of field vibration problems, since they can be quite load operates below the first critical speed. This distinction is
sensitive due to electromagnetic and mechanical force interac­ important to the balance procedures applied, in that a flexible
tion. A two pole motor can run quite well in the idle condition, shaft design requires more elaborate processing, since the

17
18
PROCEEDINGS OF THE FOURTEENTH TURBOMACHINERY SYMPOSIUM

operating speed shaft design deflections have an impact on the

results. Two pole motors in the vicinity of 2000 hp and above
are usually flexible shaft designs, due to rotor core inner
diameter (ID) restraints and are balanced to 0.00025 in radius FLUX LINES
of gyration levels or lower.
The mechanical unbalance force of a two pole rotor rotates
FIELD ROTATION
at a speed lower than that of the 60 Hz electric field. Differing
by the load induced slip, a typical 59.4 Hz value at load can be
given. Note that this slip difference provides a means to isolate
balance from other problems. The balance level for a f lexible
i MAXIMUM DENSITY
FORMING A MAGNETIC
+---+-- - t- POLE
shaft 2000 hp rotor would be 0.00025 in and would weigh close
to 1400 lb, giving an unbalance force of 64 lb at the bearings.

Fu =unbalance force=centrifugal force for rotor

=mrn2

= (1400 lb/386 in/sec2) (0.00025 in) (3600 cpm)2 (6.28/60

sec/min)2

= 129 lb total bearing force=64 lb per bearing

Figure 2. Cross Sectional Diagram of Induction Motor Show­
ing Stator and Rotor with Flux Lines.
Significant mechanical energy also exists at the second
harmonic of rotation, which, in terms of this example, would very high frequency «slot" forces and substantial harmonics are
be 2 X 59.4 Hz or 118.8 Hz. Such harmonic mechanical energy generated. Using a real time analyzer, it is quite typical to see
comes from nonlinearity and misalignment in the motor bear­ harmonic energy between ten and twenty times the 60 Hz
ings or the driver/driven shaft connection, which again is energy level and to see slot frequencies in the 1000 Hz to 2500
typical of all rotating machinery. This second harmonic energy Hz area. To be noted at this point is the fact that in the process
can cause significant vibration problems during the summation of summing the three phases of f lux spaced at 120 degree
with the 120 Hz electrical field forces which will be described positions, any phase imbalance in terms of resistance of voltage
in later sections. will add very significantly to the 120 Hz vibration force with
harmonics.
ELECTRICAL FORCES A very important factor is that the level of these magnetic
The stator winding produces three phases of sine wave pull forces is extremely high, giving a major motor design and
magnetic fields from the three power phases. This electrical field operation concern. An approximation of this force level
input is summed to give a single sine wave magnetic field in can be derived using the rule of thumb that it is approximately
the air gap, forming a north and south pole, as shown in Figure 35 psi times the rotor projected area [1]. A typical force level
1, at any instant of time. This summed f lux field varies, or for a 2000 hp two pole motor would be about 13800 lb:
rotates, at a 60 Hz rate in the air gap, as determined by the
frequency of the power supply. The magnetic f lux lines forming F m =magnetic pull
a pole in the cross-section view of a motor are indicated in the = (35 psi) (14.5 in rotor diameter) (27.5 in stack length)
plot in Figure 2. Since the magnetic field and the two poles are
= 13800 lb
rotating at 60 Hz, any point in the air gap will have these poles
pass at a frequency rate of 120 Hz. A radial magnetic pull
Asymmetry in the electric field, such as unbalanced phases or
occurs across the air gap at these poles, acting between the
unequal air gaps, can create devastating forces at the bearings
rotor and stator to give a major level force acting on the motor.
and is likely to result in major damage to the bearings. If this
same 2000 hp motor had a ten percent eccentricity in the air
gaps (nominally 0.125 in), there would be an unbalanced
Phase R /-�-�""'North Pole magnetic pull level of 1500 lb acting on the rotor. Any further
w ' . /' __ ·'-.,.--Total
eccentricity would give disproportionally greater forces, with
Q ...__,""'
.
::J / ' '-- respect to eccentricity. Magnetic pull forces are generally
1-
// -{ . - -�"""-- understood to be nonlinear over ten percent eccentricity, and
-;/;:r--+-- -r
H

_j "· '--
D.. ,?-;. I I "- '-- in the maximum case can give unbalanced pulls equal to
z Phase B j �·�-�
0: several times the weight of the rotor.
Phase C South Po I e�� ./ The mutual attraction force, or magnetic pull, acting at the
---------
air gap does place a strong action on the housing, causing stator
RNGULRR POSITION RBOUT RIR GRP 3 60 core def lections, even with a perfectly symmetrical electric
field. Thus, some 120 Hz forces will always exist. Such forces
Figure 1. Flux Density in Developed Air Gap at Instant of
will be present in all two pole motors, and in themselves will
Time t.
not cause any damage at the bearings. These forces can be seen
Note that the f lux line density is not really a continuous in many successful motor operations and should not automati­
sine wave variation in the air gap, but has discrete steps of f lux cally be considered bad. Many two pole motors have been
increase formed by the individual stator coil slots. Each slot diagnosed as having a significant problem due to the presence
adds an additional step increase in f lux at the air gap, giving an of what appears to be excessive second harmonic energy, based
approximate sine wave variation. The rotor bars also add on experience with purely mechanical machinery. Before
stepwise variations in the flux density (Figure 2), since the classifying a two pole motor with this 120 Hz condition as being
rotor tooth alignment also affects the f lux f low across the air a problem, examine its past history and determine whether the
gap. Since both of these variations are almost step increases, overall level is satisfactory.
 19
REVIEW OF FUNDAMENTAL TWO POLE INDUCTION MOTOR MECHANICS

SUMMATION OF THE FORCES AT THE F

BEARINGS u

A summary of the forces which act at the bearings of a

typical two pole motor is presented in Table 1. The mechanical
rotation is assumed to be at 59.4 Hz and is only a representa­ 59.4 Hz 60 Hz
tive level for the loaded condition. Analysis of two pole motor

v
problems will usually revolve around these regions, or at least
verifYing that they are satisfactory. The magnitudes and fre­
quencies of these individual forces are of particular interest,
along with the summation effects which may be occurring to
greatly amplifY their level.
Bearing Center
Table 1. Table of Forcing Frequencies.

Source Frequency Comments

Rotor unbalance 59.4 Hz Typical level gives Fb = mechanical unbalance

(typical) 0.40 ips vibration
F = elect rical unbalance
Electromagnetic 60 Hz Approx. 0.01 ips u
field unbalance vibration
Figure 3. Rotation Forces at the Bearing.
2nd harmonic of 2 (59.4)= Content dependent
rotation 118.8 Hz upon alignments F F
m e
Electromagnetic 2 (60)= Always present as
poles 120 Hz normal condition
Stator slot n (60)± n=number of
118.8 Hz 60 Hz
forces, 120 Hz stator slots
fundamental
Rotor slot m (60)± m=number of
forces, 120 Hz rotor slots � Bear ing Center
fundamental
F
m

F mechanical force, 2nd harmonic of rotation

The electrical and mechanical vectors near the rotation m
speed can be graphically depicted (Figure 3), while the 120 Hz F magnetic pole forces
e
area vectors are shown in Figure 4. These sets of vector pairs
are quite close in frequency and are summed at the bearings, Figure 4. Twice Rotation Area Forces at the Bearings.
leading to modulated vibration levels and "beat," causing
rather complex results. A practical way to understand this
modulation process is to visualize both rotating vectors as
w
coming in and out of phase at a rate determined by their Q
:::J
difference in speed. For instance, the rotation vectors at 60 Hz 1-
and 59.4 Hz would be in phase at the slip or difference speed of
H

_j
[]_
0.6 Hz, giving a pulsing or beating sound; a vibration meter :;::
a:
monitoring the bearings would swing between two levels at
this same rate. Similarly, the 120 Hz area vectors would be in
and out of phase at twice the slip rate, giving a 1.2 Hz pulsing
TIME, sec 10.00
vibration and sound. f 1 59.00 HZ
The waveshape summation process, as it might be seen on f2 60.00 HZ
a real time analyzer if only the two rotational area frequencies, SLIP = 1. 00 HZ
59 and 60 Hz, were present, is shown in Figure 5. The result of OR 1.00 SEC/CYCLE
this summation gives a 1.0 Hz difference modulation frequen­ Figure 5. Summation of Two Frequencies.
cy, with a period of 1.0 second per cycle. A real signal from a
two pole motor would have all of the frequencies given in Table
1 producing a much more complicated waveshape, such as that unbalance will impact the rotation area forces leading to higher
shown in Figure 6. This figure shows a two pole motor one times rotation speed area modulation. In a very similar
waveshape, with both the time plot and the frequency analysis fashion, geometrically stationary variations in the electric field
of that wave for idle operation. Note that several harmonics are or mechanical alignment will cause higher 120 Hz area modula­
present on the 400 Hz frequency plot; but the high slot tion levels. It is these two observations which can provide
frequencies are not shown on this data, since they are off scale. significant diagnostic tools for two pole motor problems.
For this idle condition, the slip speed would be so low that the The summation process of these mechanical and electrical
period of the modulation would be in minutes rather than forces also can take on linear or nonlinear results, depending
seconds and, thus, it is not really shown. Significant beat is not upon the motor condition, giving further complication to the
usually seen in the idle condition and is normally only present waveshape [2,3]. The waveshapes depicted in Figures 5 and 6
under load, as seen in the case problem presented forthwith. are linear summations, but there are nonlinear processes which
It is important to note that rotationally related variations exist in two pole motor operation, leading to very harsh
in either, or both, the rotor magnetic field or mechanical vibrational conditions. In fact,< these nonlinear processes are
20
PROCEEDINGS OF THE FOURTEENTH TURBOMACHINERY SYMPOSIUM

9 dBY
beat condition. In such cases, trim balancing or changing the
RANGE, STATUS• PAUSED
AoSTORED BK AX 23DDY IDLE
20 bearings can solve the problem.
miPS
Diagnosis of two pole motor vibration problems should
start with an examination of the 60 Hz and 120 Hz areas for the
2
miPS
presence of excessive sidebands and whether slip or twice slip
/DIY sideband frequencies predominate. The severity of the prob­
lem can be gauged by the presence of slip and twice slip low
I S �
START:
r:�· BW1 L 5
A frequency levels in the frequency or time plot. If numerous slip
sidebands predominate at 60 Hz in magnitude and level, then
0 Hz Hz STOP• 400 Hz

80 the problem is likely to be rotationally related. If strong 0.6 Hz

miPS
slip frequency is present, the problem is more severe. Strong
twice slip sidebands at 120 Hz, with or without a twice slip
20
miPS
frequency level, indicate a stationary problem related to the
/DIY bearings or the effective concentricity of the stator field. Again
the severity of the problem can be gauged by the presence of
-BD the twice slip frequency at 1.2 Hz.
STARTo
X• 60 Hz Y: 23. 18 miPSrms
A summary of possible motor/installation faults with typi­
cal effects is presented in Thble 2. This table is a general
Figure 6. Vertical Bearing Housing Vibration Level in Time and guideline to help investigate two pole motor problems in
Frequency Domains. operation under load. Each type of fault appears to be easy to
diagnose alone, but in the real case there are multiple faults
a major factor to be considered in many two pole motor
requiring some interpretation as to which is the main culprit.
problems.
Only experience and practice in resolution of such problems
Nonlinear summation of two sine waves is, at first, quite
can finally give any large degree of success with two pole
complex to understand, but with some basic review, successful
motors, but practical results can be obtained. Diagnose the
analysis of waveshapes from such processes is possible. A linear
problem in terms of the ideas presented and give alternative
summation of the two sine waves would sum just as that shown
faults which can be verified by other testing or inspection.
in Figure 5, from which an audible 1.0 Hz beat could be
detected and observed on a vibration meter. Note, however,
that in a frequency analysis of this signal, no low slip frequency CASE PROBLEM
level would be present-only the two original frequencies The case problem data in Figures 7, 8, 9 and 10 are from
would result. In a nonlinear summation process, this would not full load dynometer tests on a 600 hp motor which experienced
be the case. For instance, suppose that the waveshape in severe vibration at 0.4 ips to 0.5 ips levels in the field. In the
Figure 5 is the vertical shaft vibration which was clipped, or idle condition, the highest vibration level at the bearings was
restrained, on the negative downward side by the bearings. 0.05 ips, a very acceptable result. Full load tests on the
This means that each downward summation excursion would dynometer, however, gave results similar to th e field condition.
be clipped at the 1.0 Hz slip frequency rate. This process An averaged bearing signature for the outboard bearing show­
would be somewhat like adding a slip frequency square wave to ing 0.35 ips vibration is shown in Figure 7. The shaft vibration
the two sine waves. If a frequency plot of this summation was (in mils), with an exceptionally strong low frequency 0.6 Hz
obtained, a 1.0 Hz slip frequency component would be found nonlinear beat summation occurring, is depicted in Figure 8.
along with the two original 59 Hz and 60 Hz sine waves. A very The smaller variations riding this low frequency "square wave"
similar result would be obtained if the upward extreme summa­ are the 60 Hz and 120 Hz vibrations. A "zoom" with a real time
tion points were magnified by the magnetic pull, producing a analyzer on the rotation area showing both IX and 2X slip
distortion frequency rate equal to the slip speed. Additional sidebands is presented in Figure 9, but the 2X slip predomi­
sidebands come along with this low frequency which are nates. The 120 Hz area shows very strong 2X slip sideband
further sums and differences from the two original sine waves energy present. Audibly, the motor had a very strong pulsating
[4]. Such nonlinear processes are quite easily attained in roar at this same 0.6 Hz rate. Such results are a strong
induction motors due to the high degree of nonlinearity in the indication of stationary electrical eccentricity, which was
magnetic forces and are a major contributer to two pole motor verified in subsequent motor teardown. The air gap was found
vibration problems. In fact, air gap forces are so nonlinear that to be 20 percent eccentric, due to the stator core offset, with
the low frequency slip component can become far greater than respect to the bearing bracket to housing headfit. Removal of
the original 60 Hz or 120 Hz components (such a condition the condition cured the problem.
shown in the following case problem).
Sources of nonlinearity in a two pole motor include air gap
eccentricity, rotor eccentricity, strong variances in the mechan­
ical stiffness with respect to rotation, phase imbalance, rotor/ HARMONIC
X.60.000 Y 470.88m
stator core asymmetry, loose or broken rotor bars, and supply A SPEC
Re: 3
voltage imbalance. The electromagnetic field in an induction

IU 1.1 1. J .I .I
450.00

motor air gap creates a very nonlinear force with respect to

eccentricity, which must be carefully controlled in motor
manufacture and field operational installation. In practical MAG

terms, the nonlinearity of the magnetic pull requires that the

air gap eccentricity be maintained less than ten percent and 0. 0 . . .

0. 0 HZ 800.00
rotor core runout, with respect to the bearings, be restricted to
OUTBOARD AXIAL IPS
less than three to four mils. Excessive shaft orbit, with respect
to baring clearances, caused by either bearing problems or
very high imbalance, can result in clipping the motion or
magnifying the magnetic pull, giving a moderate nonlinear Figure 7. Bearing Signature at Full Load.
 21
REVIEW OF FUNDA?v!ENTAL TWO POLE INDUCTION MOTOR MECHANICS

Table 2 . Diagnostic Table o f ,\Jatar Faults.

Problem Eflect Comments

Eccentric air (1) 120 Hz (1) Air gap variance should be less than 10% eccentric in vertical or horiz.
gap (2) 2(s) sidebands (2) Usually will operate quite smoothly in idle condition.
w i t h s o m e low (3) Twice slip sidebands will occur at 120 Hz very strongly but will also be at 60 Hz with less predominance.
frequency s (4) In stronger cases of 20% eccentricity, very high slip frequency will occur at levels greatly exceeding the 60
(3) 120 Hz will Hz or 120 Hz levels.
be much higher
than 2(rotat.)
Rotor mnout (I) 60 Hz (l) Hotor runouts should be less than 4-5 mils.
(2) 1(s) sidebands (2) Hot rotor runouts can occur effecting the 60 and rotation level giving strong beat at slip fi·equency.
(3) Rotor cage can loosen with temp. leading to rotor bow.
Phase imbal- (l) 120 Hz (1) Similar impact as air gap eccentricity.
ance (2) Can giYe 2(s) (2) Phase imbalance can be caused bv .
sidebands �resistance imbalance,
�voltage imbalance, .5% from average is acceptable.
Interrupted (l) 60 Hz (I) Broken rotor bars, cracked bar/end ring joints, or cracked end ring.
rotor circuit (2) Several l(s) (2) Frequency of vibration depends on no. of hmlts such as the no. of broken bars.
sidebands (3) Very load sensitive and can run quite smoothly in idle condition.
(3) H i g h r o t o r (4) Rotor slot fi·equencies under load in a two pole application is ty pically 0.02-0.04 ips.
slot frequencies
can occur
Mechanical (1) Hotational (l) Mechanical unbalance should be less than 0. 5 mil at the bearings and more like 0.25 mil.
unbalance f r e q u e n c y , a p­ (2) Large imbalance can give 60 Hz or 120 Hz effect.
prox..59.4 Hz at
load.

s =slip ti·equency

X:890.62 m x,1.6877 x, 119.39 A X; 596.9.5 rn IIARIADNIC

A SPEC 1
Tl AVG 1
-
1.5000
8. 0000

..
-

� :'
Q
�
-
REAL
0. 6Hz - ;;; MAG
�

.;

�
0

�
�
-
":
l�
M
� ;::;
0

-2.0000 0.0 J\
116.00
JUI.Jl �L I

HZ
\A �JllA An A '
126.00
0. 0 SEC 4. 0000

Figure 10. Analyzer "Zoom" on 120Hz Area.

Figure 8. Full Load Shaft Vibration in Mils.

REFERENCES
x,;9.694 A X: 596.96 m
A SPEC 1 1. Alge1� P L., T he Nature o_f Polyphase Induction Machines,
�. #A:
New York: John Wiley & Sons, Inc. ( 1951).

40.000
2. Erich, F. F., " Sum and Difference in Vibration of High
Speed Rotating Machinery," Journal of Engineering for
Industry, 11-ans. ASME, pp. 181-184 (Febmary 1972).

3. Eshleman, R. E., "The Use of Sum and Difference Fre­

- quencies in Rotating Machinery Analysis, " Vibration Insti­
.,., tute Seminar Proceedings, Vibrations IV (1980) .
M
MAG
4. Maxwell, J. H., "Diagnosing Induction Motor Vibration, "
0
�

Hydrocarbon Processing (January 1981).

:;;

0.0 � A I n A

57.000 HZ 62.000

Figure 9. Analyzer "Zoom" on the Rotation Area.

22
PROCEEDINGS OF THE FOURTEENTH TURBOMACHINERY SYMPOSIUM