A STUDY OF DIFFERENT SIGNATURES BY SIMULATING FAULT CONDITIONS IN INDUCTION MOTOR

Parmatma Dubey, A. L. Hangal CG Global R&D Centre Crompton Greaves Ltd. Mumbai

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

Highlights
Major modes of failure in motors Test rig for fault study Simulation of
Bearing fault Inter-turn short Phase to phase short End ring fault

Web based Condition Monitoring System

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

Major Type of Failures in Rotating Machines

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

Test-rig

Current Clamp

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

Fault Detection Methodology

Bearing Defect Prediction: Calculation of Bearing Defect Frequency

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

Bearing Defect
(By Mechanical Vibration)

Bearing Defect Prediction: Calculation of Bearing Defect Frequency (e.g. for 6306 bearing)

No. of Balls/Rollers, Nb = 8 RPM, N = 1485 Rotor Frequency, Fr = 24.75 Hz

Reported Kurtosis Value: 4.1 Expected Kurtosis Value: 3.0

Pitch Diameter, Dc = 52 mm
Ball/Roller Diameter, Db = 12.303 mm Contact Angle, = 0 Outer Race Fault Frequency, f0 = 75.58 Hz

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

Bearing Defect
(By Motor Current Signature Analysis)

Bearing Defect Prediction: Calculation of Bearing Defect Frequency (e.g. for 6306 bearing)

Motor current signature for bearing fault.

Outer Race Fault Frequency, F0 = f1 m* fo

= 124.83 Hz.

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

Stator Winding: Phase to Phase Short

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

Rotor Fault: End ring crack

For a 4-pole motor,

RPM at full load = 1440 Supply line frequency, f1 = 49.25 Hz Synchronous speed = (120*f) / P = 1477.5 Slip, s = 0.02538 Side band frequency about supply line frequency can be given by fsb = f1(12*s) Hz. fsb = 51.75, 46.70 Hz.

Motor current signature for end ring fault

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

WEB BASED CONDITION MONITORING SYSYTEM

This programme has been developed for remote monitoring of the machine. The computer programme has been developed using National Instruments LabView software. Host software has a user friendly graphical user interface to remotely monitor the test status All fault diagnostics logics have been included in the web based programme which measures and displays the condition of the motor situated at a remote location

Configuration of Web Based Condition Monitoring System

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

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WEB BASED CONDITION MONITORING SYSYTEM

Front panel and connection status with data acquisition unit and the central server

Test panel shows overall condition of the machine

Time and frequency series plots of vibration and current can be seen in separate windows Alarm level (cut-off amplitude/frequency) is set for all parameters. A report describing overall condition of the machine can be sent to the customer in a word doc. format.

Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

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Parmatma Dubey, CG Global R&D Centre, Crompton Greaves, Mumbai, India +91-22-67558525, 9867154107. E-mail: Parmatma.Dubey@cgl.co.in

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