ERM in collaboration with research students from Curtin University has further refined and automated its Motor Current Signature Analysis (MCSA) capabilities. This will further establish ERM’s ability to identify failure modes present within a motor and provide accurate, in-depth insight into the condition of the motor.
Applications:
- Mill Motors – WIRM SCIM
- Conveyor and pump Motors
- Crusher Motors
- Wind Turbines
- All other critical motor applications
Faults that can be detected are:
- Stator / rotor bar integrity and faults
- Cracked rotor shaft / welds
- Acentric faults – such as rotor / stator
- Rotating magnetic field faults
- Low order and high order harmonics analysis
Methodology
ERM utilise state-of-the-art electrical and mechanical instruments alongside our Electrical Engineering team, who have an in-depth understanding of Motors and how to inspect, test and analyse the data. ERM have sourced a High Voltage WRI Motor for the sole purpose of Research and Development (R&D).
The following scope of work will be completed through the project:
- Develop a finite-element (FE) model using specialised software (such as LabView and MATLAB).
- Simulate healthy motor conditions of each case study.
- Comparison of healthy waveforms from the simulation to that of recorded data to validate the FE model.
- Develop an analytical model to process the electrical signal and extract the required features that correlate to specific failure modes.
- Simulate various rotor and stator faults in each case study and compare it to the raw recorded data from the test motor.
- Using the analytical model, further define and confirm failure modes using MCSA on the rotor current of a WRIM.
Conclusion
This project’s purpose is to further refine ERM’s methods to perform condition monitoring, by utilising analytical tools that model the live recordings of the frequency spectrum of an induction motor. Identifying failure modes early and planning for proactive maintenance strategies of our client’s critical assets is the outcome. This will prevent unplanned downtime and improve the safety of personnel who work in proximity of these assets in all industries.
Outcomes
- Prevention of catastrophic motor failure
- Failure Elimination by establishing and understanding of the failure modes
- Higher motor and plant reliability
- Reduced unplanned downtime





