Fault Diagnosis of Induction Machine for Rotor Cage Damage Using MCSA for Industrial Application

Abstract

The induction machine plays a vital role in industries. Induction machine failure causes significant process delays, higher maintenance expenses, and income loss. The machine’s predictive maintenance becomes crucial to find the primary cause of the defect. This paper focuses on the experimental results of induction machines used in the cement industry. Motor Current Signature Analysis is used to analyze the condition of rotor bars due to distorted input supply causing harmonics. The significance of this test is to determine the primary cause of the unexpected failure. The experimental results of the machine reveal distorted input with harmonics resulting in torque ripples. This might lead to broken rotor bars in the rotor cage with sidebands resulting in poor efficiency of the machine. Motor Current Signature Analysis predicts the lifespan of the machine to avoid unexpected failure. The Finite Element Method is used to design the machine for conditions one, two adjacent, and two non-adjacent broken rotor bars to observe the dynamics of rotor bar currents with numerical results. After a substantial overhaul of the machine, the proposed method is again performed, resulting in improved machine efficiency of 88.83%.