Harmonic current sideband indicators (HCSBIs) for broken bar detection and diagnostics in cage induction motors

Induction motor bar breakages have been increasingly studied in the last decades because of economic interests in developing techniques that permit on-line, non-invasive, early detection of motor faults in power plants. This work is specifically focused on broken bar detection and fault severity assessment in three phase power cage motors fed by non-sinusoidal voltage sources. In this work some new fault indicators for rotor bar breakages detection in squirrel cage induction motors are proposed, mathematically developed and experimentally proved. They are based on the sidebands of phase current upper harmonics, and they are well suited especially for converter-fed induction motors. The ratios I(7-2s)f/I5f and I(5+2s)f/I7f , I(13-2s)f/I11f and I(11+2s)f/I13f are examples of such new indicators, and they are not dependent on load torque and drive inertia, as classical indicators do. Their frequency-dependence has been also examined both theoretically and experimentally, and it was found less remarkable with respect to other indicators. Moreover, their values increase linearly with the quantity of consecutive broken bars, almost for not too much advanced faults; on 4-poles motors they were found quietly like the per-unit number of broken bars (ratio on total bar number). An original formulation is presented for motor mathematical modeling, based on the Generalized Symmetrical Components Theory, for sidebands amplitude computation. A complete motor model (involving all the elementary machine electrical circuits, as stator belts and rotor mesh loops) has been used for computer simulations; the same model was then transformed by using some complex Fortescue’s matrices to obtain a steady-state linear solution, solvable for stator and rotor currents, in healthy and faulty conditions. By exploiting the model, the formal definition of a set of new broken bar indicators was finally obtained. Machine simulations carried out by running the complete numerical model confirmed the accuracy of the model, and the theoretical previsions. Experimental work was performed by using a square-wave inverter-fed motor with an appositely prepared cage, for easy testing with increasing number of broken bars and without motor dismounting. Moreover, extensive experimentation was carried out on three industrial motors with different power and poles number, with increasing load, frequency and fault gravity for methodology validation. Finally, the ideas exposed in this work led to a patent application, owned by the University of Rome “Sapienza”.