Condition Monitoring of Induction Motor

          Induction motors are used worldwide as the ?workhorse? in industrial applications. Although, these electromechanical devices are highly reliable, susceptible to many types of faults .The goal of this project is to study faults occurring in such

Project Title

Condition Monitoring of Induction Motor

Project Area of Specialization

Artificial Intelligence

Project Summary

          Induction motors are used worldwide as the “workhorse” in industrial applications. Although, these electromechanical devices are highly reliable, susceptible to many types of faults .The goal of this project is to study faults occurring in such equipment’s and mainly considering a specific kind of failures, establish a methodology allowing to know between two fault detection techniques vibration analysis and motor current signature analysis (MCSA) by using STFT algorithm .We are working on single phase induction motor in which we want to diagnose the faults that occurs in induction motor which are bearing faults  and broken Rotor bar fault, these faults will be diagnose by the techniques which are motor current signature analysis (MCSA)  and vibration analysis. The vibration can be measured, using a sensor called accelerometer and MCSA technique is implemented by using current sensor. We will be working on two algorithm which are FFT and SFFT by using FPGA kit.

Project Objectives

Induction motors are the broadly used motors specially  in industries  where thousands of motors are working simultaneously in production process. If any fault occur, it can create a large breakdown in the production process and can cause large downtime. So, flawless operation is the major concern for that such a system is to be developed that can detect the faults at early stage  occurring in an induction motor to reduce large maintenance cost and heavy breakdowns. The main objective of our project is to develop a system that can detect the most common occurring faults that are  rolling bearing and rotor bar faults in an induction motor ,  by using the most widely used techniques named Motor current signature Analysis (MCSA) and vibration Analysis, Analyzing the healthy and unhealthy conditions by taking the current and vibrations of the  stator line , to provide a reliable environment in order  to avoid large shutdowns and  to continue the production process.

Project Implementation Method

The single phase induction motor is fed with 220 V supply.  The Motor current signature analysis technique is implemented by taking the current signal of the stator through current sensor  SCT-013-030 also the vibration analysis technique is used to take the vibrations of the stator through accelerometer. The data from both the current sensor and accelerometer is converted to digital using pmod module to further process it in FPGA board. Then algorithm is applied to analyze the healthy and unhealthy condition of the induction motor by spectrum analyzer.

Benefits of the Project

•   A major component of predictive maintenance. The use of condition monitoring allows maintenance to be scheduled, or other actions to be taken to prevent consequential damages and avoid its consequences.

• By detecting and notifying you when situations stress your motors, condition monitoring alerts enable you to proactively correct issues before they irreparably damage your rotating equipment..
• Reduce your energy expenses. Since motor efficiency declines with motor health, using condition monitoring to preserve the health of your motors also lowers your energy costs.
• Optimize your maintenance processes. By intervening only when your asset needs maintenance, condition monitoring enables you to eliminate unnecessary and ineffective preventive maintenance practices while still achieving high availability and reliability performance.
• Condition monitoring in industrial automation include reductions in downtime, maintenance activity and related faults, and increases in energy efficiency, yield, and quality.
• Make smarter asset management decisions. By combining sensor data, historical trends, and maintenance records to assess the current health of your motors, condition monitoring helps you to identify which motors need replacing   and which don’t. Avoiding the premature replacement of a healthy motor extends your capital investment while maintaining high availability and reliability metrics.
• Condition monitoring ’s health information enables you to make proactive, risk- and economic-based asset management decisions about the type and timing of maintenance to perform on your motor or motor-driven equipment. The induction motors require only basic maintenance and have a very low failure rate. However, the burning of the motors causes a great deal of unacceptable production losses. Consequently, diagnosing incipient faults will prevent  the problems of unexpected breakdowns of the machines and it helps in reducing the maintenance costs.
• Condition monitoring is suitable for continuous process plants where machine breakdowns can be very costly.
• To maximize the performance of the machinery.
• To enhance the failure prediction accuracy.

Technical Details of Final Deliverable

The project is to detect the bearing and broken rotor faults at early stages in an induction motor. The hardware  comprises of 0.5HP induction motor to which Nexys- 2 spartan 3E FPGA board is connected to process the data and analyze the difference between the healthy and unhealthy condition of the motor.  The Adxl 345 accelerometer sensor  is used to take the accevibration, SCT-013-030 current sensor to take the current of the stator line, Pmod ADC and Pmod DAC are used for conversion of the data from motor. The software used is  Xilinx in which chipscope tool is being used to plot the graphs of healthy and unhealthy conditions of motor taken by implementing the short time Fourier transform Algorithm.

Final Deliverable of the Project

HW/SW integrated system

Type of Industry

Medical , Food , Energy , Manufacturing

Technologies

Others

Sustainable Development Goals

Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com