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 language | English |
|---|---|
| Journal | IEEE Transactions on Industry Applications |
| DOIs | |
| Publication status | Accepted/In press - 2018 Feb 12 |
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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 journal › Article
}
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 -