Electric Current Signal Analysis for Motor Condition Monitoring

  • Yinghang He

Student thesis: Doctoral Thesis

Abstract

Induction motors are widely used in industry, making reliable and non-invasive condition monitoring significant for high-performance operations. Stator-current analysis is attractive because it is inexpensive and easy to implement. Conventional approaches, however, mainly target fault sidebands around the supply frequency, which often suffer from low signal-to-noise ratio (SNR) in practice, particularly under inverter-fed conditions where pulse width modulation (PWM) switching harmonics, winding non-idealities and fluctuating load torque, result in masking fault features. By contrast, higher-frequency components, such as those around the principal slot harmonic (PSH), are often less affected and may carry useful fault information. To address these challenges, this thesis approaches induction-motor condition monitoring through modulation signal bispectrum (MSB) analysis for stator-current feature extraction, and multiple coupled circuit (MCC) based modelling for fault-mechanism analysis and interpretation. The main contributions and findings are summarised as follows:
(1) MSB interpretation and SNR-driven parameter optimisation
The MSB is interpreted as a fourth-order moment spectrum, and its noise-reduction behaviour is characterised using simulated modulation signals. An MSB-based SNR index is then used as the objective in a systematic grid search over record length, segment length and overlap, yielding an SNR-driven MSB configuration (i.e., the parameter set that maximises the proposed index within the investigated ranges). The resulting configuration is applied not only to supply-frequency sidebands but also to higher-frequency modulation components (e.g., around the PSH).
(2) Improved MCC modelling incorporates with PWM control voltage
The MCC model is extended to incorporate sinusoidal and trapezoidal winding distributions, open-loop PWM supply and calibrated parameters. The model and simulation have found that the PWM is the main sources leading to low SNR signals. A linear simplification of dynamic-eccentricity inductances is introduced to reduce computation while preserving key spectral characteristics, enabling efficient prediction of higher-frequency fault-related sidebands, on average, the computation time is reduced by 25% while the key resulting error remains within 1%.
(3) Experimental validation and current-based diagnostic performance
The proposed modelling and MSB coherent sideband energy (CSE) analysis are assessed experimentally under inverter-fed operation for typical faults including broken-rotor-bar, eccentricity and bearing defects. Within the investigated conditions, the MSB approach increases the SNR of higher-frequency sidebands by 7–9 dB compared with reference demodulation methods and shows consistent performance across the tested data lengths. The extended MCC model reproduces measured phase currents with less than 7% RMS error and predicts higher-frequency fault-related sidebands. Experimental MSB and CSE results indicate that broken-rotor-bar and eccentricity faults remain detectable via higher-frequency modulation components under inverter-fed conditions, whereas bearing faults with 1 mm defect on race ways produce weak and statistically insignificant diagnostic signatures, which is due mainly to the large size of the motor under investigation.
Date of Award5 Feb 2026
Original languageEnglish
SupervisorFengshou Gu (Main Supervisor) & Andrew Ball (Co-Supervisor)

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