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Advances in Fault Detection, Diagnosis and Prognosis in Industrial Motors—2nd Edition

A special issue of Energies (ISSN 1996-1073). This special issue belongs to the section "F: Electrical Engineering".

Deadline for manuscript submissions: closed (15 April 2025) | Viewed by 2812

Special Issue Editor


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Guest Editor
Electrical Machines Laboratory, Department of Electrical & Computer Engineering, Democritus University of Thrace, University Campus, GR-671 00 Xanthi, Greece
Interests: electrical machines design; analysis, modeling, optimization and fault diagnosis of electrical machines; controller design; artificial intelligence methods application to electrical machines
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Special Issue Information

Dear Colleagues,

Electric motors are widely used in numerous industrial applications. They operate continuously and for long-term periods both at nominal and overload conditions. As such, it is evident that the occurrence of faults is quite frequent. A possible motor failure can lead to temporary shutdown or interruption of the production process, which results in a loss of services and/or supplies. Additionally, the Industry 4.0 framework strongly supports smart manufacturing, complying with sustainability of all the involved systems and operations. Thus, it is of great importance to proceed to fast and reliable assessment of the health status of industrial drives. The development of effective mechanisms for electric motor fault detection has therefore attracted widespread attention from both academical and industrial fields. The goal of this issue is to bring researchers together to share their research findings and present attractive perspectives in the fields of fault detection, diagnosis, and prognosis in industrial motors. Prospective authors are invited to submit original and high-quality papers. Topics of interest include but are not limited to the following areas:

  • Advanced diagnostic approaches for mechanical (e.g., bearings, gearbox, shaft bending, static and dynamic eccentricity), electrical (short circuits, winding interruption, asymmetry in supply voltage, voltage fluctuation, insulation failure, etc.), and electromechanical (rotor bars breaking, rotor end-ring detachment, etc.) faults;
  • Diagnosis of multiple simultaneous faults;
  • Early detection of incipient faults and fault isolation;
  • Multisensor data fusion;
  • Line- and inverter-fed electrical machines;
  • Signal analysis and faults diagnosis during motor operation under harsh conditions;
  • Non-invasive techniques;
  • Predictive maintenance and real-time condition monitoring systems;
  • Discrimination between faulty conditions and healthy conditions under the presence of load oscillations or speed variation;
  • Modern signal processing techniques toward information quality improvement;
  • Enhanced pattern recognition algorithms;
  • Advanced fault detection and diagnosis methods based on artificial intelligence (e.g. supervised/unsupervised machine learning).

Prof. Dr. Yannis L. Karnavas
Guest Editor

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Keywords

  • electrical machines
  • industrial motors
  • faults detection
  • diagnosis
  • artificial intelligence
  • predictive maintenance
  • industry 4.0

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Published Papers (3 papers)

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Research

24 pages, 5661 KiB  
Article
Suitability of Selected Diagnostic Factors for Assessing the Technical Condition of the Working Systems of Bucket Elevators
by Piotr Sokolski
Energies 2025, 18(7), 1610; https://doi.org/10.3390/en18071610 - 24 Mar 2025
Viewed by 255
Abstract
This article proposes a method for diagnosing the main systems of bucket elevators in order to ensure their reliable operation. This method employs diagnostic indices of vibration velocity and vibration acceleration, which were deemed useful based on tests performed on four bucket elevators [...] Read more.
This article proposes a method for diagnosing the main systems of bucket elevators in order to ensure their reliable operation. This method employs diagnostic indices of vibration velocity and vibration acceleration, which were deemed useful based on tests performed on four bucket elevators operating in a research laboratory and in a power plant. This article also analyzes other indicators, such as the coefficient of variation, skewness, kurtosis, crest factor, and quantile peak factor, and demonstrates the usefulness of kurtosis for diagnostic evaluation. Additionally, it proposes using the quantile peak factor as an alternative to the crest factor. This study estimates the statistical distributions of diagnostic signals and presents the results in the form of histograms. This is followed by the detection of outliers in all measurement series. Based on the results of the performed tests and their analysis, recommendations are made for diagnosing bucket elevators. Full article
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26 pages, 11288 KiB  
Article
Detection of Stator Faults in Three-Phase Induction Motors Using Stray Flux and Machine Learning
by Ailton O. Louzada, Wesley A. Souza, Avyner L. O. Vitor, Marcelo F. Castoldi and Alessandro Goedtel
Energies 2025, 18(6), 1516; https://doi.org/10.3390/en18061516 - 19 Mar 2025
Viewed by 446
Abstract
Three-phase induction motors are widely applied in industrial systems due to their durability and efficiency. However, electrical faults such as inter-turn short circuits can compromise performance, leading to unplanned downtime and maintenance costs. Traditional fault detection methods rely on stator current or vibration [...] Read more.
Three-phase induction motors are widely applied in industrial systems due to their durability and efficiency. However, electrical faults such as inter-turn short circuits can compromise performance, leading to unplanned downtime and maintenance costs. Traditional fault detection methods rely on stator current or vibration analysis, each with limitations regarding sensitivity to specific failure modes and dependence on motor power ratings. Despite advancements in non-invasive sensing, challenges remain in balancing fault detection accuracy, computational efficiency, and adaptability to real-world conditions. This study proposes a stray flux-based method for detecting inter-turn short circuits using an externally mounted search coil sensor, eliminating the need for intrusive modifications and enabling fault detection independent of motor power. To account for variations in fault manifestation, the method was evaluated with three different relative positions between the search coil and the faulty winding. Feature extraction and selection are performed using a hybrid strategy combining random forest-based ranking and collinearity filtering, optimizing classification accuracy while reducing computational complexity. Two classification tasks were conducted: binary classification to differentiate between healthy and faulty motors, and multiclass classification to assess fault severity. The method achieved 100% accuracy in binary classification and 99.3% in multiclass classification using the full feature set. Feature reduction to eight attributes resulted in 92.4% and 85.4% accuracy, respectively, demonstrating a trade-off between performance and computational efficiency. The results support the feasibility of deploying stray flux-based fault detection in industrial applications, ensuring a balance between classification reliability, real-time processing, and potential implementation in embedded systems with limited computational resources. Full article
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16 pages, 11838 KiB  
Article
Assessment of Suitability for Long-Term Operation of a Bucket Elevator: A Case Study
by Piotr Sokolski
Energies 2023, 16(23), 7852; https://doi.org/10.3390/en16237852 - 30 Nov 2023
Cited by 2 | Viewed by 1547
Abstract
Bucket elevators generally operate on a 24/7 basis, and for this reason, one of the main requirements is their high reliability. This reliability can be ensured, among other things, by assessing the technical condition of drive assemblies and working assemblies and taking appropriate [...] Read more.
Bucket elevators generally operate on a 24/7 basis, and for this reason, one of the main requirements is their high reliability. This reliability can be ensured, among other things, by assessing the technical condition of drive assemblies and working assemblies and taking appropriate measures. Carrying out diagnostic measurements enables periodical monitoring of those mechanisms. Vibroacoustic methods are usually employed in operating conditions to measure vibration velocity and acceleration at specific points, and are used as diagnostic signals. This paper presents the results of tests of the intensity of vibrations generated in the drive unit of a large industrial bucket elevator. The analysis of the results in the time domain and frequency domain served as the basis for evaluating the suitability of the drive, and thus the elevator, for long-term operation. Full article
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