2.

Literature Review
According to a CIRP evaluation [1], more than 50% of the machining errors even in the
case of modern machine-tools are due to the thermal phenomena. The significance and the
necessity of the study of the thermal errors is emphasized by the studies of several researches-the
majority of them being members of CIRP.

The study of thermal behavior for machine tools is very important for precision processing,
e.g. grinding. The problem is more complicated due to thermal field variations in space and time.
M.S.Popa [2] carried out the studies and the tests; these were focused on the optimization of the
Romanian grinding machines with the scope to achieve a better quality.

The accurate thermal simulation of a spot welding electrode cap [3] could permit critical
design parameters to be identified for improved electrode life. In this study, a parametric model
has been developed to predict the transient thermal behavior of a typical spot welding electrode
cap. The knowledge of temperature distribution in the electrode cap [4], [5] could be of
importance to improved electrode life and for the maintenance of spot weld quality, e.g., by
suggesting changes in the electrode design. Temperatures adjacent to the tip surface have been
measured.

In case of brushless DC motors are increasingly being employed in electric vehicles (EV)
and hybrid electric vehicles (HEV), due to their high efficiency, high power density and minimal
maintenance [6].The motor temperature is closely linked to the life and performance of brushless
DC motor. Stator winding temperature directly affects the winding insulation system’s durability
while the rotor temperature affects the efficiency of the permanent magnets [7]. Overheating in
the windings increases joule’s losses, since the electrical resistance of the winding material is
highly temperature dependent [8]. It is therefore imperative to conduct thermal analysis in the
design of brush-less DC motors. Heat generated within an electric motor comes from two
primary sources: electromagnetic losses and mechanical losses.

Lee & Kim presents transient three-dimensional thermo -hydrodynamic (3D THD) model
of radial foil bearings to predict transient thermal behavior of the bearing-rotor system. The heat
generation inside the bearing is very low, high-speed operation combined with limited heat
dissipation capability of the FB itself and inappropriate rotor system design can result in thermal
instability or thermal runaway[9,10].

Huebsch and A.John[11] developed a Vacuum cleaner with thermal cutoff is a unique and
novel air filtrating, self-propelled upright vacuum cleaner. The filtration system utilizes a HEPA-

1
rated air filter as a final filtering element. The disclosed vacuum cleaner contains numerous other
features including a self-propelled drive mechanism.

The transient thermal simulation of semiconductor chips [12] uses region-wise variable
spatial grids and variable temporal intervals, enabling spatial-temporal thermal analysis of
semiconductor chips. Temperature rates of change across a die and/or package of an integrated
circuit are computed and tracked versus time. Critical time interval(s) for temperature evaluation
are determined. Temperatures of elements, components, devices, and interconnects are updated
based on a 3D full chip temperature analysis. Respective power dissipations are updated, as a
function of the temperatures, with an automated interface to one or more circuit simulation tools.
Subsequently new temperatures are determined as a function of the power dissipations. User
definable control and observation parameters enable flexible and efficient transient thermal
analysis. The parameters relate to power sources, monitoring, reporting, error tolerances, and
output snapshots. Viewing of waveform plots and 3D spatial variations of temperature enable
efficient communication of results of the thermal analysis with designers of integrated circuits.

A gas chromatograph [13] controlled by a pair of microprocessors improved thermal

maintenance and process operation. The microprocessors are operable to run independently of
each other, with one microprocessor controlling heaters and other control devices and the other
microprocessor running a graphical user interface. The two microprocessors are separated by a
gas chromatograph assembly that includes one or more separation columns.

2.1 Temperature as a Failure Parameter

The Bearing manufacturers have long been aware of the relationship of heat to bearing life and
have designed formulas to accurately calculate safe operating temperatures. The results show a
temperature band in which both bearings and lubricants will operate at peak performance with
the least stress. Once outside the ideal temperature range, they will degrade at an accelerated
rate. So how do you interpret temperature readings, and how should they affect your
maintenance procedures? The suitable temperature-oriented method can be designed for bearing
health and life expectancy, both in the plant and in the field.

2
 Fig.2 Heat Ranges of Bearings

Fig. 2 shows the thermal range of a typical rolling element bearing. Note that bearing metal
temperature is often higher (10 to 25 degrees Celsius) than the oil temperature in the bearing
within an oil circulation system. The green zone represents the sweet spot for bearing and
lubrication temperature; operating in the yellow zone reduces lubricant and bearing life; and if
your bearings are in the red zone, expects both the bearing and the lubricant to be destroyed
rapidly.

There are different temperature bands for different combinations of bearing and lubricant, but
they will have the same general trend regarding the best operating temperature and its effect on
accelerated wear and failure. In most standard lubricants, for every 15°C increase in temperature
above 70°C, the lubricant life is more than halved and there is a negative effect on bearing life.
Any mineral oil operating at a temperature above 80°C or 90°C will have a greatly diminished
life. In no case should bearing temperature ever exceed the maximum rating of either the bearing
or the lubricant.

The overheating in electrical motors results in detrimental effects such as degradation of the
insulation materials, magnet demagnetization, increase in Joule losses and decreased motor
efficiency and lifetime. Hence, it is important to find ways of optimizing performance and
reliability of electric motors through effective cooling and consequently reduce operating and
maintenance costs. This study describes 3D CFD simulations [14] performed on a totally
enclosed air over fan cooled brushless D.C. motor to identify the temperatures of the critical
components of the motor.
According to Hoglund, Christer [15], a high viscosity composition which according to the
invention comprises at least one polyoxyethylene-polyoxypropylene-block copolymer
(poloxamer) having the structural formula HO(C.sub.2H.sub.4O).sub.a (C.sub.3H.sub.6O).sub.b
(C.sub.2H.sub.4O).sub.a H and having an average molecular weight of above 6000; at least one
additional polymer having an average molecular weight of above 150000, and a dispersion
medium, comprising at least one freezing point depressing dispersant and at least one freezing
point non-depressing dispersant. The composition is heat-able above the body temperature of a
mammal and cool-able below 0.degree. C. within a predetermined temperature range

3
3. The Problem
A white paper published by Siemens discuss the application of Smart MCC technology[16]
to standard and predictive maintenance practices used to maximize motor life and help limit
unplanned motor failure. An overview and definition of standard maintenance practices is
followed by a description of information available from a Smart MCC and how this information
can be used.
Niyompongwirat & Wararatkul [17] studied the temperature measurement and monitoring
system for industrial induction motor (Squirrel Cage Rotor Motor). The aim of temperature
monitoring system is to analyze and alarm an abnormality of the motor and prevent the damage
in case of unbalance voltage. This system was tested by an induction motor of pointing machine.
The experiment setup consists of a temperature measurement circuit using IC LM 35DZ with
analog transformer used as a temperature sensor and transducer and the personal computer with
data acquisition card from National Instrument PCI 6014 using Lab View version 7.1 for
analyzing temperature data. The AC source was performed by adjusting voltage unbalance of
10%, 20% to 50% for each phase to monitor the temperature changes. This scheme can alert the
operation of the motor in order to prevent damage and to extend the life time reducing
maintenance costs.
Three phase induction motors are widely used in industrial, commercial and residential systems,
because of their ruggedness, simplicity and relatively low cost. Approximately 65% of the
electricity consumed in industry is used to drive electrical motors. Therefore, the efficiency and
reliability of induction motors operation is of major importance, in order to improve the energy
efficiency in industry [18]. Squirrel cage induction motors are the most important AC machines
in industry. Low cost, high reliability, low inertia and high transient torque capacity are among
the advantages of these motors. Many resources show that 35%–45% of motor failures are
caused by stator insulation breakdown. For small induction machines, thermal overloading is one
of the major causes of the stator winding insulation degradation process [19].
Thermal devices and models, which assume fixed thermal characteristics of the motor, are not
capable of providing sufficient thermal protection since they have no means of giving a correct
temperature estimate when the thermal characteristics change. Therefore, in order to extend the
insulation life, it is critical to monitor the stator winding temperature and protect the motor under
thermal overloading conditions such as motor stall, jam, overload, unbalanced operation, and
situations where the cooling ability of the motor is accidentally reduced [20]. The stator
temperature can also be estimated based on the stator resistance measurement and another
accurate method deals with the direct measurement of motor heating using temperature sensors
installed in stator windings and rotor parts[21],[22]. The stator temperature has been obtained
using two methods, which are temperature measurement with sensor installing method and DC
injection method. Each method is implemented on the 1.1kW/ 50Hz/ 1400rpm three-phase
4
squirrel cage induction motor. For verifying the DC injection method, different tests have been
done under unbalance condition [23], [24].
Researches about the deteriorating of induction motors under unbalanced voltage conditions
have been reported in the literature since 1959 .The most accurate method for deteriorating under
unbalanced voltage conditions is to reduce the induction motor load so as to limit the
temperature rise to the normal value. The complexity of the thermal behavior of an induction
motor under unbalanced voltages makes necessary the development of experimental studies with
an accurate measurement of the temperature inside the motor; however in the literature few
experimental works with this methodology are reported [24].
The purposed of this paper is to detect the temperature of induction motor for unbalance phase
analysis, we apply the effects of thermal to define the abnormal operation of both mechanical
and electrical of the motor by adjust the unbalance voltage source of 10%,20%,30%,40% and
50%. Aim of research is to find an appropriate method to improve the efficiency of the three
phase induction motor
The experiment results of the phase unbalance on the induction motor can be determined the
abnormal operation by the heating effect. The changing of AC voltage source generates the
unbalance voltage of 10%, 20% to 50% for each phase in order to monitor the temperature
behavior. The temperature of the motor increases at higher rate after phase imbalance greater
than 30% of unbalance voltage showing the difference of temperature. The phase voltage should
be always balanced by monitoring and defining the suitable period of maintenance. This situation
can alert the operation of the motor in order to prevent damage and to extend the life time
reducing maintenance costs as well.

3.1 Monitoring Thermal Behavior

The current monitoring of thermal behavior is conducted through vibration analysis, oil analysis
and/or ultrasound techniques. Through these, it is possible to compare current data to historical
data and accurately assess the life of the bearings. The temperature increases due to increase in
friction is not even considered as a symptom of bearing failure in many bearing analysis texts
until Stage 3 bearing failure occurs. If temperature is a reliable method of bearing life prediction,
why is it ignored until after it's too late? The monitoring of temperatures with thermography has
been considered unreliable because so many variables such as ambient temperature, speed, load
and runtime all have a pronounced influence on bearing temperature.

The temperature differences between the two bearings on a common shaft with the same load,
can only be the result of friction, an indicator of bearing problems. Perhaps subtle changes are
hidden because there are so many variables that can potentially contribute to bearing
temperature. In addition to friction, other factors that can contribute to temperature variation are
load, speed, and ambient environment temperature and runtime duration. If these conditions
could be predicted and accounted for accurately, then increases in temperature would reliably

5
indicate bearing problems. In most cases vibration analysis and oil analysis are still the best ways
to determine bearing health. Unfortunately, it's not always possible or affordable to use these
methods in hostile production environments. Any environments where staff or technicians cannot
easily access the machine without taking it offline, or cannot access the machine due to
hazardous conditions or inconvenient locations make vibration or oil analysis expensive at best,
or even impossible.

There are many industries and production environments where bearing failure represents
catastrophic loss, yet vibration analysis is not practical. Photographic film and paper
manufacturing, chemical processing and metalworking plants are a few examples of industries
that depend greatly on bearings, but where bearing accessibility can be a major problem. Most
manufacturers have at least some vital equipment in areas that are not easily accessible.

Jaworski & J.M.Hawkins, [25] presents results from experiments of high resolution mapping of
the internal temperatures of Valve-regulated lead-acid (VRLA) batteries on float duty. The
internal thermal conditions of mono-block VRLA batteries during different operating conditions
have been characterized. The dynamic behavior of the batteries during thermal runaway is
reported

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5. Benefits of Study
This research will help in an improving the present industrial maintenance practice based on
behavioral study without considering the thermal behavior of system for component failures.