journal article·2025-02-08Open access

Comparative Analysis of the Effect of Rotor Faults in the Performance of Low-Speed High-Torque Machines

Carlos Madariaga-Cifuentes, Cesar Gallardo, Jose E. Ruiz-Sarrio, Juan A. Tapia, Jose A. Antonino-Daviu

Applied Sciences· Volume 15· Issue 4

Abstract

Several studies have focused on modeling and analyzing the impact of rotor faults in conventional low-pole-count machines, while related research on low-speed high-torque (LSHT) machines with a high pole count remains limited. In these machines, the combination of low speed, high inertia, and high torque levels presents a critical application for advanced diagnosis techniques. The present paper aims to describe and quantify the impact of rotor faults on the performance of LSHT machine types during the design stage. Specifically, 10-pole and 16-pole synchronous reluctance machines (SynRMs), permanent magnet synchronous machines (PMSMs), and squirrel-cage induction machines (SCIMs) are assessed by means of detailed 2D simulations. The effects of eccentricity, broken rotor bars, and partial demagnetization are studied, with a focus on performance variations. The results show that LSHT PMSMs are not significantly affected by the partial demagnetization of a few magnets, and the same holds true for common faults in SynRMs and SCIMs. Nonetheless, a significant increase in torque ripple was observed for all evaluated faults, with different origins and diverse effects on the torque waveform, which could be hard or invasive to analyze. Furthermore, it was concluded that specialized diagnosis techniques are effectively required for detecting the usual faults in LSHT machines, as their effect on major performance indicators is mostly minimal.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Engineering Diagnostics and Reliability · Engineering Technology and Methodologies · Mechanical Systems and Engineering

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

Department of Electrical Engineering, University of Concepcion, Concepcion 4070386, Chile

Power Electronics, Machines, and Control Research Institute, University of Nottingham, Nottingham NG7 2RD, UK

Instituto Tecnológico de la Energía, Universitat Politècnica de València, 46022 Valencia, Spain

Funding

AGENCIA NACIONAL DE INVESTIGACION Y DESARROLLO · Spanish ‘Ministerio de Ciencia e Innovación’ · Agencia Estatal de Investigación and FEDER program · “Plan Estatal de Investigación Científica, Técnica e Innovación 2021-2023”

References (67)

Show source-provided references
1. Antonino-Daviu, J.A., Zamudio-Ramirez, I., Osornio-Rios, R.A., and Dunai, L. (2023, January 11–13). Fault Diagnosis in Electric Motors through the Analysis of Currents and Stray Fluxes. Proceedings of the 2023 International Conference on Electromechanical and Energy Systems (SIELMEN), Craiova, Romania.10.1109/SIELMEN59038.2023.10290820 ↗
2. Condition Monitoring and Fault Diagnosis of Induction Motor10.1007/s42417-020-00253-y ↗
3. Liu, Z., Zhang, P., He, S., and Huang, J. (2021). A Review of Modeling and Diagnostic Techniques for Eccentricity Fault in Electric Machines. Energies, 14.10.3390/en14144296 ↗
4. Fault diagnosis techniques for permanent magnet ac machine and drives—A review of current state of the art10.1109/TTE.2018.2819627 ↗
5. Allianz Insurance (2001). Monitoring und Diagnose Elektrischer Maschinen und Antriebe, VDE Colloquium.
6. Modified Efficiency Estimation Tool for Three-Phase Induction Motors10.1109/TEC.2022.3219097 ↗
7. Condition Monitoring of Industrial Electric Machines: State of the Art and Future Challenges10.1109/MIE.2020.3016138 ↗
8. Faiz, J., Joksimovic, G., and Ghorbanian, V. (2017). Fault Diagnosis of Induction Motors, Institution of Engineering & Technology.10.1049/PBPO108E ↗
9. An Overview of Techniques for Detecting Mechanical Anomalies in Induction Motors10.1007/s41403-023-00446-3 ↗
10. Condition Monitoring and Fault Diagnosis of Induction Motors: A Review10.1007/s11831-018-9286-z ↗
11. Health Monitoring and Fault Diagnosis in Induction Motor-A Review
12. Induction Motors Fault Diagnosis Using Finite Element Method: A Review10.1109/TIA.2019.2958908 ↗
13. Li, X., Tian, X., Wang, Y., Zhao, R., and He, W. (2019, January 11–14). Analysis of Vibration and Noise of IPMSM for Electric Vehicles under Inverter Harmonic in a Wide-speed Range. Proceedings of the 2019 22nd International Conference on Electrical Machines and Systems (ICEMS), Harbin, China.10.1109/ICEMS.2019.8921880 ↗
14. Rotor Design Optimization of a New Flux-Assisted Consequent Pole Spoke-Type Permanent Magnet Torque Motor for Low-Speed Applications10.1109/TMAG.2018.2832076 ↗
15. Wu, D., Xu, J., Han, Z., Lin, H., and Shao, P. (2023, January 27–29). Research on Proper Fractional-Slot Concentrated Winding Characteristics for A High Thrust Force Ultra-Low Speed Tubular PM Linear Machine. Proceedings of the 2023 IEEE International Conference on Applied Superconductivity and Electromagnetic Devices (ASEMD), Tianjin, China.10.1109/ASEMD59061.2023.10369389 ↗
16. Electromagnetic and Structural Design of a Novel Low-Speed High-Torque Motor With Dual-Stator and PM-Reluctance Rotor
17. Madariaga, C., Gallardo, C., Tapia, N.R.J.A., Jara, W., and Degano, M. (IEEE Trans. Energy Convers., 2024). Design and Evaluation of Matrix Rotor Induction Motor for High-Torque Low-Speed Applications, IEEE Trans. Energy Convers., early access.10.1109/TEC.2024.3426480 ↗
18. Liang, B.X., Wang, D.Z., Zhang, B.Y., and Xu, G.R. (2019, January 3–5). Research of Low-Power Low-Speed Squirrel-cage Motor. Proceedings of the 2019 Chinese Control and Decision Conference (CCDC), Nanchang, China.
19. Design of Novel Axial-Flux Dual Stator Doubly Fed Reluctance Machine10.1109/TMAG.2015.2444382 ↗
20. A Novel Methodology for the Demagnetization Analysis of Surface Permanent Magnet Synchronous Motors
21. Experimental and Simulation Studies of Partial Demagnetization Process of Permanent Magnets in Electric Motors10.1109/TEC.2021.3082903 ↗
22. Li, Q., Ma, C., Wang, P., and Zhang, X. (IEEE Trans. Transp. Electrif., 2024). Analytical Model for IPMSMs with Mixed Eccentricity Considering the Effect of Eccentricity on Core Saturation, IEEE Trans. Transp. Electrif., early access.10.1109/TTE.2024.3435758 ↗
23. Detection of Eccentricity Faults in Three-Phase Reluctance Synchronous Motor10.1109/TIA.2012.2199453 ↗
24. Eccentricity in Synchronous Reluctance Motors—Part I: Analytical and Finite-Element Models10.1109/TEC.2014.2384535 ↗
25. Effect of Magnetic Forces and Magnetostriction on the Stator Vibrations of a Bearingless Synchronous Reluctance Motor10.1109/TMAG.2019.2894739 ↗
26. Imeryuz, M., Mergen, A.F., and Ustun, O. (2010, January 14–16). A method to analyze asynchronous machines with broken rotor bars. Proceedings of the SPEEDAM 2010, Pisa, Italy.10.1109/SPEEDAM.2010.5545157 ↗
27. Sittisrijan, N., and Ruangsinchaiwanich, S. (2010, January 10–13). Investigation of the broken bar effect on the squirrel cage induction motor by FEM. Proceedings of the 2010 International Conference on Electrical Machines and Systems, Incheon, Republic of Korea.
28. Muteba, M. (2023). Analysis of a Three-Phase Induction Motor with a Double–Triple-Layer Stator Winding Configuration Operating with Broken Rotor Bar Faults. Machines, 11.10.3390/machines11111023 ↗
29. Fireteanu, V., Constantin, A.I., and Popa, M. (2018, January 3–6). Influence of Single or Multiple Faults Short-circuit, Broken Rotor Bar and Eccentricity on the Torque and Rotor Force in Induction Motors. Proceedings of the 2018 XIII International Conference on Electrical Machines (ICEM), Alexandroupoli, Greece.10.1109/ICELMACH.2018.8507008 ↗
30. Kedjar, B., Merkhouf, A., and Al-Haddad, K. (2020, January 23–26). Large Synchronous Machines Diagnosis Based on Air-Gap and Stray Fluxes—An Overview. Proceedings of the 2020 International Conference on Electrical Machines (ICEM), Gothenburg, Sweden.10.1109/ICEM49940.2020.9270868 ↗
31. Diagnosis of Multiple Defects Within Large Hydroelectric Generator Using Stray Flux and Air Gap (Distance and Flux) Measurements10.1109/TIA.2024.3441519 ↗
32. Review of Artificial Intelligence Methods for Faults Monitoring, Diagnosis, and Prognosis in Hydroelectric Synchronous Generators10.1109/ACCESS.2024.3502546 ↗
33. Zhou, J., Fang, H., Li, R., Qu, R., and Li, D. (2022, January 5–8). Research on Sensitivity of Slot-Pole Combination to Unbalanced Electromagnetic Force Introduced by Rotor Eccentricity. Proceedings of the 2022 International Conference on Electrical Machines (ICEM), Valencia, Spain.10.1109/ICEM51905.2022.9910907 ↗
34. Effect of Inclined Static Eccentricity Fault in Single Stator-Single Rotor Axial Flux Permanent Magnet Machines10.1109/TMAG.2011.2161876 ↗
35. Magnetic Field Calculation in Axial Flux Permanent Magnet Motor with Rotor Eccentricity
36. Riquelme, D., Madariaga, C., Jara, W., Bramerdorfer, G., Tapia, J.A., and Riedemann, J. (2023). Study on Stator-Rotor Misalignment in Modular Permanent Magnet Synchronous Machines with Different Slot/Pole Combinations. Appl. Sci., 13.10.3390/app13052777 ↗
37. Jeyasankar, E., Ahsanullah, K., Zhenzhen, X., and Panda, S.K. (2017, January 4–7). Local demagnetization fault diagnosis for Surface Permanent Magnet based marine propulsion motor. Proceedings of the 2017 IEEE 3rd International Future Energy Electronics Conference and ECCE Asia (IFEEC 2017—ECCE Asia), Kaohsiung, Taiwan.10.1109/IFEEC.2017.7992173 ↗
38. Frosini, L. (2020). Novel diagnostic techniques for rotating electrical machines—A review. Energies, 13.10.3390/en13195066 ↗
39. McMillan, R.B. (2020). Rotating Machinery: Practical Solutions to Unbalance and Misalignment, River Publishers.
40. A comparative study of current, vibration and stray magnetic flux based detection for parallel misalignment fault in induction motors10.1109/SDEMPED51010.2021.9605507 ↗
41. Corne, B., Knockaert, J., and Desmet, J. (September, January 29). Misalignment and unbalance fault severity estimation using stator current measurements. Proceedings of the 2017 IEEE 11th International Symposium on Diagnostics for Electrical Machines, Power Electronics and Drives (SDEMPED), Tinos, Greece.10.1109/DEMPED.2017.8062363 ↗
42. Eliminating rare earth permanent magnets on low-speed high-torque machines: A performance and cost comparison of synchronous reluctance machines, ferrite permanent magnet-synchronous reluctance machines and permanent magnet synchronous machines for a direct-drive elevator system10.1049/elp2.12032 ↗
43. Kou, S., Kou, Z., Wu, J., and Wang, Y. (2022). Modeling and simulation of a novel low-speed high-torque permanent magnet synchronous motor with asymmetric stator slots. Machines, 10.10.3390/machines10121143 ↗
44. A survey on low speed low power axial flux generator design and optimization using simulation10.1016/j.neucom.2022.07.004 ↗
45. Rotor surface ferrite permanent magnets in electrical machines: Advantages and limitations10.1109/TIE.2017.2677320 ↗
46. Detection and classification of rotor demagnetization and eccentricity faults for PM synchronous motors10.1109/TIA.2012.2191253 ↗
47. Detection of trailing edge PM demagnetization in surface PM synchronous motors10.1109/TIA.2023.3247402 ↗
48. Stator Current Spectral Content of Inverter-Fed Cage Rotor Induction Motor10.1109/ACCESS.2022.3154481 ↗
49. Application of Ring Winding in Induction Motor10.1109/TASC.2021.3107809 ↗
50. Advanced analysis of motor currents for the diagnosis of the rotor condition in electric motors operating in mining facilities10.1109/TIA.2018.2818671 ↗
51. Rotor-bar breakage mechanism and prognosis in an induction motor
52. Analysis and diagnostics of adjacent and nonadjacent broken-rotor-bar faults in squirrel-cage induction machines10.1109/TIE.2008.2011341 ↗
53. A Novel Flux Barrier Parametrization for Synchronous Reluctance Machines
54. Study on Analysis and Design of Line-Start Synchronous Reluctance Motor Considering Rotor Slot Opening and Bridges
55. Gallardo, C., Madariaga, C., Tapia, J.A., and Degano, M. (2023). A Method to Determine the Torque Ripple Harmonic Reduction in Skewed Synchronous Reluctance Machines. Appl. Sci., 13.10.3390/app13052949 ↗
56. Ban, B., and Stipetic, S. (2022). Systematic metamodel-based optimization study of synchronous reluctance machine rotor barrier topologies. Machines, 10.10.3390/machines10080712 ↗
57. Navarro-Navarro, A., Ruiz-Sarrio, J.E., Biot-Monterde, V., Antonino-Daviu, J.A., Becker, V., and Urschel, S. (2023). Application of transient analysis techniques to fault diagnosis in Low-and medium-power synchronous machines. Machines, 11.10.3390/machines11020288 ↗
58. Synchronous reluctance machines: A comprehensive review and technology comparison10.1109/JPROC.2022.3145662 ↗
59. Pryhönen, J., Jokinen, T., and Hrabovcová, V. (2014). Design of Rotating Electrical Machines, John Wiley & Sons.10.1002/9781118701591 ↗
60. Modern Electrical Machine Design Optimization: Techniques, Trends, and Best Practices10.1109/TIE.2018.2801805 ↗
61. Optimization of Electric Machine Designs−Part I10.1109/TIE.2017.2753359 ↗
62. Active Broken Rotor Bar Diagnosis in Induction Motor Drives10.1109/TIE.2020.3007108 ↗
63. Madariaga-Cifuentes, C., Ruiz-Sarrio, J.E., Antonino-Daviu, J.A., Gallardo, C., and Tapia, J.A. (2024, January 1–4). Broken Bar Detection of Axial-Flux Induction Machines Through Advanced Transient Current Signature Analysis. Proceedings of the 2024 International Conference on Electrical Machines (ICEM), Torino, Italy.10.1109/ICEM60801.2024.10700107 ↗
64. Ullah, Z., Lee, S.-T., Siddiqi, M.R., and Hur, J. (October, January 29). Online Diagnosis and Severity Estimation of Partial and Uniform Irreversible Demagnetization Fault in Interior Permanent Magnet Synchronous Motor. Proceedings of the 2019 IEEE Energy Conversion Congress and Exposition (ECCE), Baltimore, MD, USA.10.1109/ECCE.2019.8912744 ↗
65. Candelo-Zuluaga, C., Riba, J.-R., Thangamuthu, D.V., and Garcia, A. (2020). Detection of Partial Demagnetization Faults in Five-Phase Permanent Magnet Assisted Synchronous Reluctance Machines. Energies, 13.10.3390/en13133496 ↗
66. Lopez, C.A., Babel, A.S., and Strangas, E.G. (2016, January 4–7). Detecting uniform and partial demagnetization for an interior permanent magnet machine. Proceedings of the 2016 XXII International Conference on Electrical Machines (ICEM), Lausanne, Switzerland.10.1109/ICELMACH.2016.7732931 ↗
67. Calculation of the Iron losses in a Spoke-Type Permanent Magnet Synchronous In-Wheel Motor for Electric Vehicles by Utilizing the Bertotti Model10.1109/TMAG.2019.2902164 ↗