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

doi:10.1109/TIA.2018.2805828

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

School of Electrical Engineering

Research output: Contribution to journal › Article › peer-review

4 Citations (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 offline and online 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 offline 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-D finite element analysis and experimental testing on closed and semiopen slot aluminum die cast rotors of 5.5 kW induction motors with porosity.

Original language	English
Pages (from-to)	2246-2254
Number of pages	9
Journal	IEEE Transactions on Industry Applications
Volume	54
Issue number	3
DOIs	https://doi.org/10.1109/TIA.2018.2805828
Publication status	Published - 2018 May 1

Keywords

Aluminum die-cast rotor
fault detection
fill factor
induction machines
porosity
quality assurance
squirrel cage rotor

ASJC Scopus subject areas

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

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10.1109/TIA.2018.2805828

Cite this

@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 offline and online 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 offline 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-D finite element analysis and experimental testing on closed and semiopen slot aluminum die cast rotors of 5.5 kW induction motors with porosity.",

keywords = "Aluminum die-cast rotor, fault detection, fill factor, induction machines, porosity, quality assurance, squirrel cage rotor",

author = "Myung Jeong and Jangho Yun and Yonghyun Park and Lee, {Sang Bin} and Gyftakis, {Konstantinos N.}",

note = "Funding Information: Manuscript received November 6, 2017; revised February 3, 2018; accepted February 9, 2018. Date of publication February 12, 2018; date of current version May 18, 2018. Paper 2017-EMC-1393.R1, presented at the 2017 IEEE 11th International Symposium on Diagnostics for Electrical Machines, Power Electronics, and Drives, Tinos, Greece, Aug. 29–Sep. 1, and approved for publication in the IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS by the Electric Machines Committee of the IEEE Industry Applications Society. This research was supported in part by the Basic Science Research Program through the National Research Foundation of Korea (NRF) funded by the Ministry of Education under Grant 2016R1D1A1A09917190, and in part by the Human Resources Program in Energy Technology of the Korea Institute of Energy Technology Evaluation and Planning granted financial resources from the Ministry of Trade, Industry, and Energy, Republic of Korea, under Grant 20154030200610. (Corresponding author: Sang Bin Lee.) M. Jeong, J. Yun, Y. Park, and S. B. Lee are with the Department of Electrical Engineering, Korea University, Seoul, 02841, South Korea (e-mail: jeongmyung03@gmail.com; ydh7999@hhi.co.kr; yonghyun.park@eecs. korea.ac.kr; sangbinlee@korea.ac.kr). Publisher Copyright: {\textcopyright} 1972-2012 IEEE.",

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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.

N1 - Funding Information: Manuscript received November 6, 2017; revised February 3, 2018; accepted February 9, 2018. Date of publication February 12, 2018; date of current version May 18, 2018. Paper 2017-EMC-1393.R1, presented at the 2017 IEEE 11th International Symposium on Diagnostics for Electrical Machines, Power Electronics, and Drives, Tinos, Greece, Aug. 29–Sep. 1, and approved for publication in the IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS by the Electric Machines Committee of the IEEE Industry Applications Society. This research was supported in part by the Basic Science Research Program through the National Research Foundation of Korea (NRF) funded by the Ministry of Education under Grant 2016R1D1A1A09917190, and in part by the Human Resources Program in Energy Technology of the Korea Institute of Energy Technology Evaluation and Planning granted financial resources from the Ministry of Trade, Industry, and Energy, Republic of Korea, under Grant 20154030200610. (Corresponding author: Sang Bin Lee.) M. Jeong, J. Yun, Y. Park, and S. B. Lee are with the Department of Electrical Engineering, Korea University, Seoul, 02841, South Korea (e-mail: jeongmyung03@gmail.com; ydh7999@hhi.co.kr; yonghyun.park@eecs. korea.ac.kr; sangbinlee@korea.ac.kr). Publisher Copyright: © 1972-2012 IEEE.

PY - 2018/5/1

Y1 - 2018/5/1

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 offline and online 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 offline 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-D finite element analysis and experimental testing on closed and semiopen 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 offline and online 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 offline 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-D finite element analysis and experimental testing on closed and semiopen slot aluminum die cast rotors of 5.5 kW induction motors with porosity.

KW - Aluminum die-cast rotor

KW - fault detection

KW - fill factor

KW - induction machines

KW - porosity

KW - quality assurance

KW - squirrel cage rotor

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

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Keywords

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