IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 52, NO. 2, MARCH/APRIL 2016 1469
Induction Motor Rotor Bar Damage EvaluationWith Magnetic Field Analysis
Scott W. Clark, Senior Member, IEEE, and Daniel Stevens, Member, IEEE
Abstract—Detection of defects in induction machine rotor barsfor disassembled motors are required to evaluate machines consid-ered for repair as well as fulfilling incremental quality assurancechecks in the manufacture of new machines. Detection of rotorbar defects prior to motor assembly are critical in increasingrepair efficiency and assuring the quality of newly manufac-tured machines. Many methods of detecting rotor bar defects inunassembled motors lack the sensitivity to find both major andminor defects in both cast and fabricated rotors along with addi-tional deficiencies in quantifiable test results and arc-flash safetyhazards. A process of direct magnetic field analysis can examinemeasurements from induced currents in a rotor separated fromits stator yielding a high-resolution fingerprint of a rotor’s mag-netic field. This process identifies both major and minor rotor bardefects in a repeatable and quantifiable manner appropriate fornumerical evaluation without arc-flash safety hazards.
Index Terms—AC machines, ac motors, electromagneticmeasurements, induction motors, magnetic flux, rotors.
I. INTRODUCTION
D ETECTION of rotor bar defects in disassembled motorsis a common testing need for induction motors being
evaluated for repair, or in the manufacturing process. Detectingrotor bar defects early in the work process aids in timely andhigh-quality construction of induction motors. Often evaluationof a rotor must be performed without its host stator due to man-ufacturing workflow, or in the case of repair due to an electricalfailure of the stator. Disassembled offline testing has uniquechallenges with respect to many assembled or online testingmethods where methods such as rotor influence current (RIC),testing, single-phase rotation testing, motor current signatureanalysis (MCSA), and synchronous flux monitoring methodsall which require a functional stator to identify rotor bar defects[1]–[4].
Rotor bar defects can be grouped into two major categories:1) major and 2) minor defects. Minor defects can be caused bypoor rotor bar to end ring connections or metallurgical flaws.Major defects can be described as broken rotor bars wherethe rotor bar has become completely disconnected from itsend ring. Techniques for evaluating rotor bar health with a
Manuscript received September 23, 2015; revised November 23, 2015;accepted November 25, 2015. Date of publication December 17, 2015; dateof current version March 17, 2016. Paper 2015-EMC-0763.R1, presented atthe 2015 IEEE Symposium on Diagnostics for Electric Machines, PowerElectronics and Drives, Guarda, Portugal, September 1–4, and approved forpublication in the IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS bythe Electric Machines Committee of the IEEE Industry Applications Society.
Color versions of one or more of the figures in this paper are available onlineat http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TIA.2015.2508424
rotor in a disassembled offline configuration start with a sim-ple visual inspection [1]. Visual inspection may be successfulfor major defects while minor defects will remain undetected.Cast rotors are particularly difficult to evaluate due to the rotorbar to end ring interface being unavailable for visual inspection[5]. Beyond visual inspections, many techniques exist to detectrotor bar defects including dye penetration, ultrasonic testing,growler hacksaw tests, growler iron fillings tests, growler volt-age monitoring tests, growler magnetic field viewing film tests,rotor rated flux testing, digital low-resistance ohm-meter mea-surements (DLRO), and ELCID [1]–[3], [5]. Testing techniquesrequiring electrical connections to bars or end rings may requiremodification of the rotor in the form of drilled and tappedprovisions for test source and probe connections.
Some of these tests present a substantial risk of arc-flash orelectrical shock to the operator since they must contact an ener-gized rotor as part of the testing procedure. Other tests suchas the rotor rated flux test, also referred to as high currentexcitation, run the risk of damaging the rotor permanently bygenerating temperatures at defect locations capable of causinga mechanical deformation of the rotor shaft.
Many of the available disassembled offline rotor tests aredeficient in one or more categories of test performance suchas the ability to detect both major and minor defects or electri-cal safety. A new testing method referred to as rotor magneticfield analysis (RMFA) has shown promise in resolving many ofthese challenges. A list of disassembled offline tests along withseveral assembled offline test methods and the features of eachtest is summarized in Table I.
The most common test methods for disassembled offlinerotor testing utilize magnetic viewing film. Many facilities use agrowler apparatus to induce a current in rotor bars under evalu-ation and use magnetic field viewing film to detect the presenceof a magnetic field for each rotor bar as seen in Fig. 1. Theabsence of a magnetic field when a growler is applied to therotor represents a major rotor bar defect such as a broken rotorbar.
Although considered one of the advanced rotor bar defectdetection techniques, the use of magnetic field viewing filmcannot detect minor rotor bar defects and as with all growlertechniques exposes the test operator to substantial electricalshock and arch flash hazards. Only three of the existing offlinedisassembled rotor bar defect detection techniques can iden-tify a minor rotor bar defect: 1) DLRO; 2) ultrasound; and3) ELCID. While the DLRO test is effective in minor defectdetection, it cannot be universally applied with all rotor designssuch as cast rotors without modification to the rotor to allow forthe connection of the test apparatus. Ultrasound has deficiencies
1470 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 52, NO. 2, MARCH/APRIL 2016
TABLE IROTOR BAR DEFECT OFFLINE TEST METHODS
Fig. 1. Growler in use with magnetic field viewing film.
associated with the difficulty of interpreting test results [3].Finally, ELCID testing, while effective in minor defect detec-tion, exposes the operator to electrical hazards from the excitingsource, and is not applicable on all rotors due to Chattock coilspan limitations [3].
To overcome the deficiencies of current rotor bar defect test-ing, a new testing technique should be developed. Lookingtoward several rotor testing techniques and their associated ben-efits and limitations, we find the inspiration for a new approach.The growler magnetic viewing film method is effective on allrotor types without modification, but lacks the sensitivity to findanything more significant than a broken rotor bar [1]. Single-phase rotation testing utilizes the stator connected in such amanner as to achieve a nonrotating sinusoidal flux, which canbe used to find variations in the rotor cage impedance as therotor is rotated, but lacks the required sensitivity and requiresa functional stator [1], [2], [4]. Synchronous flux monitoringused for online analysis of wound rotor short circuit faults
Fig. 2. RMFA test topology.
uses a flux probe to identify variations in salient pole wind-ings with a high degree of sensitivity while requiring a fullyfunctional stator and online testing conditions [2]. A combi-nation of the testing techniques mentioned can serve as thebasis for a new offline disassembled rotor test. Utilizing thebasic components of a growler test, the process of rotating arotor while detecting rotor circuit impedance variations, andthe utilization of a magnetic flux probe as measurement basis,an ideal offline disassembled test can be specified. A new testmethod was developed in which direct magnetic field measure-ments of a rotor are performed to evaluate rotor bar defects.This test procedure generates a fingerprint of the rotor that canbe numerically evaluated to detect both major and minor rotorbar defects. A rotor fingerprint is unique between each rotorand can be compared over the lifecycle of the motor to predictrotor health. This process of RMFA is performed with the rotorin an automated test stand with no operator contact with therotor required [6]–[8]. RMFA testing solves many of the prob-lems associated with unassembled rotor bar defect detectionproviding a highly sensitive test with recordable results whilerisking no damage to the rotor or exposing testing personnel toelectrical hazards.
II. CONFIGURATION
The process of RMFA testing is performed by directly mea-suring the magnetic field produced by each rotor bar whenthe rotor is exposed to a single phase inducing 60 Hz mag-netic field. The RMFA test topology along with a finite-elementmodel (FEM) of the test conditions are seen in Figs. 2 and 3.
Unlike traditional growler testing, the exciter used is notplaced into direct contact with the rotor and is held at a min-imum air-gap to allow the rotor to be rotated slowly duringtesting. An exciter positioned within an excitation plane is sep-arated axially along the rotor length from a detection planewhere magnetic field measurements are made. Current researchutilizes a small commercially available 720 W growler as theexciter source.
Consistent air-gap for the exciter and measurement probe iscritical for test repeatability with rotor fingerprint comparisons.A balancing machine serves as a good platform for RMFA anal-ysis. A precision magnetometer with data acquisition capability
CLARK AND STEVENS: INDUCTION MOTOR ROTOR BAR DAMAGE EVALUATION 1471
Fig. 3. RMFA FEM.
is used for rotor magnetic field detection. A transverse or tan-gential probe, typically, a linear Hall Effect sensor, used withthe magnetometer is necessary for RMFA testing. Axial andomnidirectional probes are not applicable with this testing tech-nique. It is important to select a magnetometer with a widefrequency range, ideally dc to 60 Hz or higher. Although theexciter coil operates at 60 Hz, the ability to measure dc fields ishelpful in identifying rotors with permanent magnetization thatcould artificially bias testing.
With a tangential probe, the magnetic B field must be tan-gential to the probe surface for maximum probe response. Thisfeature yields a large detection signal when the probe is directlyabove a rotor bar and a low signal when the probe is cen-tered directly between rotor bars [Fig. 4(a) and (d)]. The probeshould be positioned above an area of the rotor where rotor coresteel is present. If the probe is placed above an area withoutrotor core steel such as a radial air duct area or an area towardthe end ring on a fabricated rotor, the magnetic field variationbetween rotor bars will not be pronounced enough to detectminor defects. The placement of the probe within the core steelenvelope results in the measurement of a consistently shapedmagnetic field pattern that transitions from alignment with theprobe to tangential to the probe yielding high sensitivity in bardetection and analysis. The flux measurement when the probeis between rotor bars or above a rotor tooth is lower than whenabove a rotor bar [Fig. 4(d)]. This varying flux pattern is thebasis for RMFA analysis and fingerprinting. A damaged rotorbar having a higher impedance than an undamaged bar will pro-duce detectable difference in magnetic flux as seen in Fig. 4(b)and (e), and a broken rotor bar produces a pronounced impactto the flux pattern in comparison to an undamaged bar [Fig. 4(c)and (f)].
With the magnetometer probe situated appropriately, therotor can be rotated by a driving mechanism such as a belt-and gearbox-coupled motor. The speed of rotation must bematched to the acquisition speed of magnetometer hardware.The required speed is often much slower than conventionaldrive motors installed on balancing machines are capable of;
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special drive mechanisms are often required. Typical rotationrates required for RMFA testing are on the order of 0.2 rpmmaximum, which is governed by the acquisition speed ofthe magnetometer. Magnetometer readings can be recordedwith data acquisition hardware for posttest numerical analysis.Magnetometers with measurement ranges of 5 µT–10 mT allowfor minor rotor bar damage detection.
With traditional growler techniques, the detection methodsneed to be placed on the top of a rotor with the associatedgrowler on the bottom of the rotor (Fig. 1). This opposing sidestopology is the least efficient topology possible, requiring largeinduced fields to create a detectable rotor bar magnetic fieldon the opposite side of the rotor. With the RMFA technique, itis not necessary to measure the induced rotor bar field on anopposite side of the rotor, allowing for a reduction in excitercoil power. The exciter or growler power requirements for tra-ditional magnetic viewing film testing vary with the size of therotor being tested. As an example, a 6000 hp 900 rpm squirrelcage induction rotor required 58 kVA using a custom 480 V60 Hz growler for successful magnetic viewing film testing.The same rotor required 537 VA for RMFA testing. This powerrequirement example shows the advantage of RMFA for largerotors with this scenario requiring ~1% the power needed forgrowler testing.
It should be noted that although the probe positioning of themagnetometer is colocated on the same side of the rotor as theexciter, the probe should be placed as far away axially alongthe rotor from the exciter as possible. Ideally, the exciter wouldbe placed on the end of the rotor and the probe on the oppositeend with both aligned and centered over the same initial rotorbar (Fig. 2). It is recommended to adopt a consistent setup pro-cedure with defined exciter and probe-positioning guidelinesalong with consistent rotation direction with respect to the driveend of the rotor.
A typical RMFA excitation condition would consist of a 3–5 mm air-gap for both the exciter and the field sensor withrespect to the rotor surface. The exciter is operated with a60 Hz single-phase 120 V supply for convenience and sim-plicity of using mains power. It is not anticipated that smallchanges to supply frequency, i.e., 50 Hz, would impact the test-ing effectiveness substantially. An excitation level resulting ina flux density of 100–200 mT in the air-gap has been usedsuccessfully keeping the exciter and field sensor separated bya minimum of 300 mm axially. This setup process allows forthe identification of suspect rotor bar defects in the recordedRMFA data and the subsequent physical identification of thosesuspected defects on the rotor. With a proper configuration, anoscillating magnetic field signature should be present as eachbar passes the magnetometer probe (Fig. 5).
Closed slot rotor designs may require higher exciter flux den-sities to prevent a reduction in sensitivity. This difference inrequired exciter flux density stems from the rotor core bridg-ing the top of a rotor bar in a closed slot construction topology.The slot closure provides a flux path reducing the magnetic fluxdensity in the air above the rotor surface. Excitation levels threetimes that of normal test parameters may be required dependingon slot closure depth.
Fig. 5. Rotor bar magnetic field pattern detected with rotation.
Fig. 6. Rotor bar magnetic field pattern repeatability tests.
The RMFA test method is highly repeatable. To demon-strate the repeatable nature of test results when using consistentprocedures such as exciter and probe air-gap and placementpositions, two tests were performed on the same rotor (Fig. 6).The first repeatability test was performed marking a 0◦ startingposition and recording the magnetic field pattern for a full 360◦
of rotation. To eliminate the possibility of the first test influ-encing the second test, the rotor was removed from the testingapparatus at the conclusion of test #1 and placed on the floor fora duration of 4 h. After this testing pause, the rotor was preparedfor a second repeatability test with the test starting at the 180◦
position relative to the first test. Comparison of repeatabilitytests #1 and #2 indicate a high degree of consistency (Fig. 7).Experience with RMFA testing has yielded an expectation ofrepeatability within ±2.5%. Further examination of the datacollected during RMFA repeatability testing shows a variationin the magnetic flux density pattern at ∼180◦. The deviationsin magnetic flux density peaks found in these repeatability testswere investigated and found to be caused by several cold solderjoints in the bar to end ring connection interface.
III. ROTOR CONSTRUCTION CONSIDERATIONS
Using the RMFA testing method, the process of detectingrotor cage circuit defects can be biased by some rotor con-struction features. It is important to consider the possibility ofunanticipated rotor construction features in the analysis pro-cess of RMFA magnetic flux patterns. If an RMFA plot is
CLARK AND STEVENS: INDUCTION MOTOR ROTOR BAR DAMAGE EVALUATION 1473
Fig. 7. Rotor bar magnetic field repeatability comparison.
Fig. 8. Rotor construction with back iron nonuniformity.
Fig. 9. Rotor bar magnetic field pattern with construction anomaly.
observed with a per bar variability that also contains a patternor some symmetry, further investigation of the rotor should beperformed to prevent an incorrect testing conclusion.
The topology of the rotor core may on some occasions cre-ate a variance in RMFA patterns. As an example, consider arotor design for a slow speed application which utilizes a spi-der construction between the rotor shaft and rotor core (Fig. 8).If the spider is constructed from rotor core material, it maycreate a variable flux path that is ultimately reflected in anRMFA pattern (Fig. 9). The back iron of this design com-prised a spider with 8 spokes attributable to the RMFA patternanomaly.
Another rotor construction feature that should be consid-ered is the rotor bar slot closure found in closed slot rotor
Fig. 10. Residual magnetization pattern.
TABLE IIRMFA RESULTS—TEST 1
designs. As mentioned, this slot closure can reduce RMFAsensitivity. Additionally, this slot closure is susceptible to resid-ual magnetization after a motor has been operated. Residualmagnetization can be detected prior to RMFA testing usinga magnetometer cable of detecting a static field and record-ing the magnetic flux density pattern while rotating the rotorwith no applied excitation (Fig. 10). Special attention shouldbe placed on removing any residual magnetization of the rotorspecimen. Failure to degauss rotors under examination couldprevent accurate testing.
Although not a challenge for rotor testing during manufac-ture, residual magnetization of the rotor must be reduced toprevent artificially biasing the test results. It has been found thatdegaussing the rotor to a level less than 0.1 mT is an effectivethreshold. If magnetization is discovered, the process of demag-netization can be accomplished with a solenoidal coil largerthan the rotor diameter and a variable dc power supply used ina down-cycle technique [9]. Current RMFA research is focusedon eliminating sensitivity to residual magnetization.
IV. TEST INTERPRETATION CRITERIA
Automatic numerical analysis of the RMFA magnetometerdata is possible, preventing the need for operator interpreta-tion. The only inputs necessary for analysis in addition to therotor bar magnetic field fingerprint is the bar to bar magneticfield pattern variance allowed. This value is determined by therepair or manufacture facility and is still subject to research.The RMFA test set uses a bar index marking and tracking tech-nique to determine when a 360◦ fingerprint is complete. With a360◦ fingerprint supplied to a numerical processing algorithm,a peak and trough identification algorithm is applied. For each
1474 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 52, NO. 2, MARCH/APRIL 2016
Fig. 11. RMFA—test 1 setup.
Fig. 12. RMFA—test 1 results.
trough pair and associated peak, an average trough magnitudeto peak magnitude value is calculated. The maximum of alltroughs to peak values is used as the baseline to compare alltrough to peak bar field readings using the supplied allowedvariance. Any bar field readings falling below the defined min-imum variance are marked as a suspected minor defect on theRMFA fingerprint. For each peak identified in the RMFA fin-gerprint, a peak-to-peak separation distance is calculated. Thesmallest peak-to-peak separation value is used as the baseline tocompare all peak-to-peak separation calculations. If any peak-to-peak separation calculations exceed the baseline by 25%,then the midpoint of that peak-to-peak separation is the spa-tial location of a broken bar. With the minor and major defectcalculation processes, each bar in a rotor can be identified andits electrical performance relative to the other bars is analyzedand reported.
Experience with the RMFA testing technique and match-ing flux pattern deviations to physical defects has lead to theselection of a 50%–65% defect detection threshold for use withopen-slot rotors. A lower variance threshold of 25% has beenadopted for closed-slot rotors. It has been observed that closed-slot rotors have more flux pattern deviation by default. This
TABLE IIIRMFA RESULTS—TEST 2
Fig. 13. Damaged rotor bar example—test 2.
Fig. 14. RMFA—test 2 results.
behavior is still not fully understood, but is thought to be a resultof porosity formations in the casting process of closed-slotrotors.
V. EXPERIMENTAL RESULTS
Using the RMFA technique, a known defect-free rotor wastested along with a known damaged rotor. The results for thedefect-free rotor summarized in Table II and Figs. 11 and 12demonstrates a typical RMFA fingerprint in which peak-to-peak bar field variability is found with low trough-to-trough
CLARK AND STEVENS: INDUCTION MOTOR ROTOR BAR DAMAGE EVALUATION 1475
Fig. 15. RMFA—test 2 results with growler magnetic viewing film testing comparison.
magnitude variability. The experimental test results wereevaluated using a numerical method with a 65% variancethreshold.
The RMFA results for a rotor with known defects summa-rized in Table III and Fig. 14 demonstrate a common defectRMFA fingerprint. An example of a damaged bar defect areais presented in Fig. 13 in which the end ring to bar connectionhas been compromised but not broken. The defect RMFA fin-gerprint contains large peak-to-peak bar field variability withhigh trough-to-trough magnitude variability. The experimentalresults were evaluated using a numerical method with a 65%variance threshold. The numerical analysis method identifiesseveral rotor bars with minor defects along with one rotor barthat exhibits a major defect.
Based on the RMFA experimental results in test 1 and test2, it is clear that rotor bar defects can be detected algorith-mically in an automated manner. Both broken rotor bars anddamaged rotor bars are detected by the defect algorithm withresults seen in Fig. 14, and presented along with the results ofconventional growler magnetic viewing film results for com-parative examination (Fig. 15). The RMFA defect algorithmwhich has been developed automatically detects the maximumand minimum in the magnetic field pattern and identifies bro-ken or damaged rotor bars based on the predefined magneticfield pattern variance threshold.
All known rotor bar defects detected in test 2 were inde-pendently verified through visual inspection with no detectionerrors via RMFA occurring. Visual examination identified thedefect type as areas of damaged rotor bar to end ring con-nection brazing. Examination of magnetic viewing film resultshighlight the limitations of conventional testing methods inwhich minor defects detected via RMFA cannot be definitivelyidentified with magnetic viewing film.
VI. CONCLUSION
The technique of RMFA offers a method of detecting majorand minor defects in rotors in a repeatable manner. The result-ing data from RMFA testing are useful for detecting a varietyof rotor bar flaws along with providing the ability to gener-ate a rotor fingerprint for future comparison. Unlike other rotortesting techniques, the RMFA testing does not require opera-tor contact with energized equipment reducing electrical shockand arc-flash hazards inherent to other techniques with poorelectrical safety.
RMFA provides advantages as a testing framework whichimproves upon available rotor bar testing methods applicablefor disassembled offline testing. The combination of repeata-bility, record-ability, electrical safety, and the ability to detectmajor and minor defects with automatic analysis is unique inthe choices available for disassembled offline rotor bar test-ing. With the RMFA technique, testing the quality control ofunassembled squirrel cage rotors can be improved allowing forthe timely and accurate diagnosis of rotor bar defects.
REFERENCES
[1] T. Bishop, “Squirrel cage rotor testing,” in Proc. EASA Conv., SanFrancisco, CA, USA, Jun. 2003.
[2] G. C. Stone, I. Culbert, E. A. Boulter, and H. Dhirani, ElectricalInsulation for Rotating Machines: Design, Evaluation, Aging, Testing,and Repair, 2nd ed. Hoboken, NJ, USA: Wiley, 2014.
[3] S. L. Nau, D. Schmitz, and W. de Lima Pires, “Methods to evaluate thequality of stator and rotor of electric motors,” in Proc. IEEE 10th Int.Symp. Diagn. Elect. Mach. Power Electron. Drives (SDEMPED), Sep.1–4, 2015, pp. 64–70.
[4] T.-J. Kang, J. Kim, S. B. Lee, and C. Yung, “Experimental evaluationof low voltage off-line testing for induction motor rotor fault diagnos-tics,” in Conf. Rec. Annu. Pulp Paper Ind. Tech. Conf., Jun. 22–26, 2014,pp. 127–136.
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[5] G. C. Stone and I. Culbert, “The testing tools,” IEEE Ind. Appl. Mag.,vol. 14, no. 6, pp. 48–53, Nov./Dec. 2008.
[6] S. W. Clark and D. Stevens, “Induction motor rotor bar damage evalua-tion with magnetic field analysis,” in Proc. 10th IEEE Int. Symp. Diagn.Elect. Mach. Power Electron. Drives (SDEMPED), Sep. 1–4, 2015,pp. 39–43.
[7] S. W. Clark and D. Stevens, “Squirrel cage induction motor cast rotordefect detection with magnetic field analysis,” in Proc. Int. Conf. Elect.Mach. Syst. (ICEMS’15). Oct. 25–28, 2015, Paper 27P4-9.
[8] S. W. Clark, “A new method of testing rotor bars,” Elect. Apparatus,vol. 68, pp. 29–33, Sep. 2015.
[9] M. Rohner, Demagnetization of Large Surface Objects Before Welding.Grüningen, Switzerland: Maurer Magnetic AG, 2015, p. 8.
Scott W. Clark (M’98–SM’13) was born inLubbock, TX, USA. He received the B.Sci. degree inelectrical engineering and the B.Sci degree in com-puter science from Texas Tech University, Lubbock,TX, USA, in 2002, and the M.Sc. degree in electricaland computer engineering from The Johns HopkinsUniversity, Baltimore, MD, USA, in 2005.
Since 2005, he has been with Brandon and ClarkInc., Lubbock, TX, USA, where he is currently theDirector of Engineering and Operations. His researchinterests include electrical apparatus manufacture and
repair, insulation systems, and testing.
Daniel Stevens (M’14) was born in Houston, TX,USA. He is currently studying engineering at TexasTech University and South Plains College, LubbockTX, USA.
He joined Brandon and Clark Inc., Lubbock, TX,USA, in 2012, where he is currently a ResearchEngineer. His research interests include electri-cal apparatus construction, maintenance, repair, andtesting.
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