Heat and fatigue, associated with excessive motor starts or overloading can lead to broken rotor bars in electric motors. Broken rotor bars eventually lead to motor failure, and can cause secondary damage to stator windings. Rotor bar damage can be difficult to detect in a vibration signature. Emerson’s CSI Motor Diagnostic technology, with embedded analysis expertise, helps complete a total Machinery Health Management programme by diagnosing electrical problems that may be missed with a vibration monitoring programme alone.
Motor current analysis provides information on rotor-related electrical faults such as broken rotor bars, high-resistance joints, voids in aluminum cast rotors, and cracked rotor end rings in squirrel-cage induction motors.
In addition to motor current analysis, Emerson’s motor monitoring tools also include motor flux analysis. Monitoring the magnetic flux field of the motor provides the safety and convenience of not having to open motor control cabinets to access electrical wiring directly, and provides detection of additional electrical problems related to the motor stator that are not found in the current signature. Temperature measurements also play an important role in the overall motor condition analysis and are incorporated into the automated analysis.
The tools are non-intrusive and perform motor current analysis, motor flux analysis and temperature measurements while motors remain online. Motor signature data is transferred to AMS Suite: Machinery Health Manager for automated expert analysis, trending, comparison with results from other diagnostic technologies, and implementation of corrective actions.
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Vibration is movement relative to a reference position, such as the centre line of a shaft on rotating equipment. It is a result of an excitation force or forcing function and may be either random or periodic. This is why vibration analysis for machinery is important to undertake.
Vibration monitoring can often pinpoint a failing element of a rotating machine in time to avoid catastrophic failure and costly replacement of machinery as well as lengthy production interruptions.
- Each machine fault generates a specific vibration pattern.
- The frequency of the vibration is determined by the machinery geometry and operating speed.
- A single vibration measurement provides information about multiple components.
Vibration Monitoring Can Identify The Following Problems
- Belt Problems
- Oil Whirl
- Vane pass
- Rolling element bearing defects
- Electrical Problems
- Sleeve bearing problems
- Flow problems
- Lubrication problems
- Gear problems
- Oil Whip
- Blade pass
- Pipe Strain
Vibration monitoring is used to improve profitability in every major industry in the world.