Health Monitoring and Current Signature Analysis of Industrial Three Phase Motors

Project Title

Health Monitoring and Current Signature Analysis of Industrial Three Phase Motors

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

Many Industries are appointing operators to monitor health of Motors Manually. To Monitor these parameters manually, The operator should be present 24/7 which requires manual personnel.  But in this project we are Monitoring all the parameters in a smart way and everything will be displayed on HMI screen. We are monitoring real time current of motor by data acquisition. Monitoring a health of motor and all other parameters which can cause a motor to burn out can let us know the early fault detection of abnormalities in the motors and it will help to avoid expensive failures. when we energize  any electrical  motor so the current gets maximum (Inrush Current) which is harmful for Motor’s Winding therefore we are designing Star-Delta Starter. We will also monitor a Torque of Motor as well as Vibration of Motor .Till now there is no such condition monitoring system available in Pakistani industries and markets  that can be used to monitor such factors of the motors and machines with the help of this project we can easily tackle these sort of problems and it can safe many resources as well as manual personnel work will be reduced.

Many Industries are appointing operators to monitor health of Motors Manually. To Monitor these parameters manually, The operator should be present 24/7 which requires manual personnel.

 But in this project we are Monitoring all the parameters in a smart way and everything will be displayed on HMI screen. We are monitoring real time current of motor by data acquisition. Monitoring a health of motor and all other parameters which can cause a motor to burn out can let us know the early fault detection of abnormalities in the motors and it will help to avoid expensive failures. when we energize  any electrical  motor so the current gets maximum (Inrush Current) which is harmful for Motor’s Winding therefore we are designing Star-Delta Starter. We will also monitor a Torque of Motor as well as Vibration of Motor .Till now there is no such condition monitoring system available in Pakistani industries and markets  that can be used to monitor such factors of the motors and machines with the help of this project we can easily tackle these sort of problems and it can safe many resources as well as manual personnel work will be reduced.

Project Objectives

Automation and Digitalization are the requirement of every well-developed Industry for the sake of Automatic Controlling , Monitoring & Safety. This idea presents a proposed scheme for Health monitoring and safety of three phase Industrial  motor.

3-Phase  Motors are most widely used electrical machines for industrial, domestic and commercial applications.  Motors are undoubtedly reliable but we cannot avoid the possibility of failure also. These failure conditions are taking place due to its component failure. If the failure occurs in the machine that failure ought to be diagnose as early as possible. If these failure conditions are not diagnosed on time so the failed components will effect whole motor operation badly and will become more catastrophic. Consequently, large revenue losses and maintenance will be needed. Different types of Parameters include Monitoring of Stator current, overload , Temperature rise, vibration,  Inrush current, Direction of rotor. Therefore there is a strong demand for reliable and safe operation. If any fault occurs It can lead to excessive downtimes and generate great losses in term of revenue  and maintenance.

Project Implementation Method

Our Project is designed to Monitor & protect of  Industrial Motor  in a smart way through PLC and HMI. The purpose of making this project is to ensure the safety of Industrial Machines from different incidents. We have got to research on data acquisition of real time Motor’s current .  Due to high temperature Motor’s winding can burn thus we must Monitor the temperature as well. We are designing the circuit to avoid inrush current and also for overload and overcurrent protection. All these parameters will be controlled by PLC and monitor on HMI. PLC is more reliable and efficient than Micro-Controller and Arduino for Industrial Application and HMI is the only way where Human being and Machines can communicate to each other.

Benefits of the Project

From decades there is no such thing applicable in the  industries or available in the market to monitor real-time motor parameters and it’s health. We are taking initiative for the advancement of industries . Due to this idea personnel involvement will be exempted. Previously a person has to sit 24/7 to observe the on-time parameters that was a hectic task for the industry owners because they have to hire a staff that work in shifts for this on-time observation.Due to this innovative idea Automation in the industries will be achieved and manual personnel will be  removed.

Technical Details of Final Deliverable

Automation in industry is achieved and efficiency of the motors is enhanced, life span of the motors enhance as we will resolve the problems in time that will prevent motors from burning ,cost effectiveness will be achieved  due to the minimization of manual personnel.

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther IndustriesCore Technology OthersOther TechnologiesSustainable Development Goals Industry, Innovation and InfrastructureRequired Resources

Elapsed time in (days or weeks or month or quarter) since start of the project	Milestone	Deliverable
Month 1	Background	Research
Month 2	Objective	Research
Month 3	Circuit Designing	Block Diagram
Month 4	Simulation	Circuit Diagram
Month 5	Purchasing of components and electronic devices and Testing the implemented Circuits	checking the authenticity of our fabricated circuitry.
Month 6	Start Report Writing and PLC Programming	Designed Ladder Logic for this project
Month 7	Interfacing Sensors with Transmitters	Generated required Signal for PLC input Module
Month 8	Star-Delta Starter	Avoid Inrush /Starting Current
Month 9	Integration with PLC	Controlled all the parameters through PLC
Month 10	Final Hardware Implementation	Merge all the Hardware together
Month 11	Interfacing PLC with HMI	Monitored the PLC output signal
Month 12	Completion of the project	Final Report and Testing