Quality Assurance Testing for Screening Defective Aluminum Die-cast Rotors of Squirrel Cage Induction Machines

Myung Jeong, Jangho Yun, Yonghyun Park, Sang Bin Lee, Konstantinos N. Gyftakis

Research output: Contribution to journalArticle

1 Citation (Scopus)

Abstract

The recent trend in squirrel cage induction motor manufacturing is to replace fabricated copper rotors with aluminum die-cast rotors to reduce manufacturing cost to stay competitive in the global market. Porosity in aluminum die-cast squirrel cage rotors is inevitably introduced during the die cast process. Porosity can cause degradation in motor performance and can lead to a forced outage causing irreversible damage in extreme cases. Many off-line and on-line quality assurance test methods have been developed and applied for assessment of rotor quality. However, years of experience with the existing test methods revealed that they are not suitable for quality testing or capable of providing a quantitative assessment of rotor porosity with sufficient sensitivity. In this paper, a new off-line test method capable of providing sensitive assessment of rotor porosity is proposed. It is shown that rotors with minor and distributed porosity that are difficult to detect with other tests can be screened out during manufacturing. The proposed method is verified through a 3 dimensional finite element analysis and experimental testing on closed and semi-open slot aluminum die cast rotors of 5.5 kW induction motors with porosity.

Original languageEnglish
JournalIEEE Transactions on Industry Applications
DOIs
Publication statusAccepted/In press - 2018 Feb 12

Fingerprint

Quality assurance
Screening
Rotors
Aluminum
Porosity
Testing
Induction motors
Squirrel cage motors
Sciuridae
Outages
Copper
Finite element method
Degradation
Costs

Keywords

  • Aluminum Die-cast Rotor
  • Bars
  • Fault Detection
  • Fill Factor
  • Induction Machines
  • Induction motors
  • Porosity
  • Probes
  • Quality assurance
  • Quality Assurance
  • Rotors
  • Squirrel Cage Rotor
  • Testing

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Industrial and Manufacturing Engineering
  • Electrical and Electronic Engineering

Cite this

Quality Assurance Testing for Screening Defective Aluminum Die-cast Rotors of Squirrel Cage Induction Machines. / Jeong, Myung; Yun, Jangho; Park, Yonghyun; Lee, Sang Bin; Gyftakis, Konstantinos N.

In: IEEE Transactions on Industry Applications, 12.02.2018.

Research output: Contribution to journalArticle

@article{95536d988a594596a725bb27243ba8ae,
title = "Quality Assurance Testing for Screening Defective Aluminum Die-cast Rotors of Squirrel Cage Induction Machines",
abstract = "The recent trend in squirrel cage induction motor manufacturing is to replace fabricated copper rotors with aluminum die-cast rotors to reduce manufacturing cost to stay competitive in the global market. Porosity in aluminum die-cast squirrel cage rotors is inevitably introduced during the die cast process. Porosity can cause degradation in motor performance and can lead to a forced outage causing irreversible damage in extreme cases. Many off-line and on-line quality assurance test methods have been developed and applied for assessment of rotor quality. However, years of experience with the existing test methods revealed that they are not suitable for quality testing or capable of providing a quantitative assessment of rotor porosity with sufficient sensitivity. In this paper, a new off-line test method capable of providing sensitive assessment of rotor porosity is proposed. It is shown that rotors with minor and distributed porosity that are difficult to detect with other tests can be screened out during manufacturing. The proposed method is verified through a 3 dimensional finite element analysis and experimental testing on closed and semi-open slot aluminum die cast rotors of 5.5 kW induction motors with porosity.",
keywords = "Aluminum Die-cast Rotor, Bars, Fault Detection, Fill Factor, Induction Machines, Induction motors, Porosity, Probes, Quality assurance, Quality Assurance, Rotors, Squirrel Cage Rotor, Testing",
author = "Myung Jeong and Jangho Yun and Yonghyun Park and Lee, {Sang Bin} and Gyftakis, {Konstantinos N.}",
year = "2018",
month = "2",
day = "12",
doi = "10.1109/TIA.2018.2805828",
language = "English",
journal = "IEEE Transactions on Industry Applications",
issn = "0093-9994",
publisher = "Institute of Electrical and Electronics Engineers Inc.",

}

TY - JOUR

T1 - Quality Assurance Testing for Screening Defective Aluminum Die-cast Rotors of Squirrel Cage Induction Machines

AU - Jeong, Myung

AU - Yun, Jangho

AU - Park, Yonghyun

AU - Lee, Sang Bin

AU - Gyftakis, Konstantinos N.

PY - 2018/2/12

Y1 - 2018/2/12

N2 - The recent trend in squirrel cage induction motor manufacturing is to replace fabricated copper rotors with aluminum die-cast rotors to reduce manufacturing cost to stay competitive in the global market. Porosity in aluminum die-cast squirrel cage rotors is inevitably introduced during the die cast process. Porosity can cause degradation in motor performance and can lead to a forced outage causing irreversible damage in extreme cases. Many off-line and on-line quality assurance test methods have been developed and applied for assessment of rotor quality. However, years of experience with the existing test methods revealed that they are not suitable for quality testing or capable of providing a quantitative assessment of rotor porosity with sufficient sensitivity. In this paper, a new off-line test method capable of providing sensitive assessment of rotor porosity is proposed. It is shown that rotors with minor and distributed porosity that are difficult to detect with other tests can be screened out during manufacturing. The proposed method is verified through a 3 dimensional finite element analysis and experimental testing on closed and semi-open slot aluminum die cast rotors of 5.5 kW induction motors with porosity.

AB - The recent trend in squirrel cage induction motor manufacturing is to replace fabricated copper rotors with aluminum die-cast rotors to reduce manufacturing cost to stay competitive in the global market. Porosity in aluminum die-cast squirrel cage rotors is inevitably introduced during the die cast process. Porosity can cause degradation in motor performance and can lead to a forced outage causing irreversible damage in extreme cases. Many off-line and on-line quality assurance test methods have been developed and applied for assessment of rotor quality. However, years of experience with the existing test methods revealed that they are not suitable for quality testing or capable of providing a quantitative assessment of rotor porosity with sufficient sensitivity. In this paper, a new off-line test method capable of providing sensitive assessment of rotor porosity is proposed. It is shown that rotors with minor and distributed porosity that are difficult to detect with other tests can be screened out during manufacturing. The proposed method is verified through a 3 dimensional finite element analysis and experimental testing on closed and semi-open slot aluminum die cast rotors of 5.5 kW induction motors with porosity.

KW - Aluminum Die-cast Rotor

KW - Bars

KW - Fault Detection

KW - Fill Factor

KW - Induction Machines

KW - Induction motors

KW - Porosity

KW - Probes

KW - Quality assurance

KW - Quality Assurance

KW - Rotors

KW - Squirrel Cage Rotor

KW - Testing

UR - http://www.scopus.com/inward/record.url?scp=85042127565&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=85042127565&partnerID=8YFLogxK

U2 - 10.1109/TIA.2018.2805828

DO - 10.1109/TIA.2018.2805828

M3 - Article

AN - SCOPUS:85042127565

JO - IEEE Transactions on Industry Applications

JF - IEEE Transactions on Industry Applications

SN - 0093-9994

ER -