Real-Time Defect Detection of Die Cast Rotor in Induction Motor Based on Circular Flux Sensing Coils

The die cast rotor bars in production squirrel cage induction motors (SCIMs) are easily subjected to porosity or other defects in production, which considerably affects the motors’ reliability and efficiency in operation. Planar flux sensing coils have been investigated for the defect detection of SCIM rotor. However, these types of sensors cannot accurately evaluate the severity of porosity or broken bar. This article develops a novel instrument to inspect and quantitatively analyze the rotor quality of SCIM. The sensor consists of the electromagnetic flux sensing coils directly from an SCIM stator. By injecting a dc voltage at phases A and B of the sensor, the induced voltage signal is generated from phase C. A quantitative fault indicator (QFI) is constructed on the basis of the instrument voltage output. The variation trend of the QFI with respect to fault severity is investigated by establishing a theoretical sensor model. Experimental results indicate that the proposed method can accurately detect the porosity and broken bar, and evaluate their severities for the die cast rotor. The developed solution can be easily implemented with low cost and computational complexity, which can achieve real-time inspection of SCIM rotor in theline.