Flux-based Detection of Non-adjacent Rotor Bar Damage in Squirrel Cage Induction Motors

Detection of rotor cage faults in induction motors based on motor current signature analysis (MCSA) is being extensively applied in the field for preventing forced outage of the motor and industrial process. Although MCSA is very effective for detecting broken bars that are adjacent to each other, it can fail if the broken bars are non-adjacent, which is common for applications with frequent starts. If multiple broken bars are spread out at locations where the rotor "electrical" asymmetry is canceled, the presence of broken bars is difficult to detect with MCSA. A false indication can lead to a catastrophic forced outage, but the only known means of detecting this type of fault in the field is through rotor visual inspection. In this paper, the feasibility of detecting non-adjacent broken rotor bars from the rotor rotational frequency sideband components in the internal and external flux measurements during steady state and motor starting is evaluated. Experimental testing on a 7.5 hp induction motor shows that non-adjacent broken bars can be reliably detected from the analysis of flux measurements for cases where MCSA and all other electrical tests fail.