In this research, a model is presented to detect and monitor the rotor bar’s condition of large motors. This proposed model uses two diagnostic methods MCSA and ZCT, to extract the fault components. The input of the proposed model is only the motor current at two levels of 80% and 100% of the nominal motor load, which by using the two methods MCSA and ZCT and making changes in how to use them can be the disadvantages of other methods such as incorrect detection of rotor bars in Large motors with variable load, the harmonical stator voltage (or the presence of the drives) and asymmetric conditions. The extracted components are classified using neural network, instead of experimental and human resources constraints. Using this classification algorithm is high accuracy and the ability to implement in conventional processors. The proposed model has been trained andtested using currents of real large motor data and 96.87% accuracy using neural network to detect faults and monitor the online status of the rotor bars. On the other hand, the proposed model has been implemented in the industrial environment (FiroozkoohCement Factory) and has been able to correctly determine the rotor bars of 4 large suspicious motors announced by the factory technicians.

Fault detection at the early stage of development is of great importance in the maintenance of electric motors. In this regard, Motor Current Signature Analysis (MCSA) is cited in many articles to detect rotor bar fracture. The popularity of MCSA is due to its non-invasive and non-destructive nature, simplicity, and, compatibility with several signal processing tools. The vast variety of the signal processing tools which are commonly used for detecting the broken rotor bar fault is based on the Fast Fourier Transform (FFT) of the stator current signal and analysis of the produced Fourier spectrum; however, because of the small amplitude at the fault frequency relative to the main frequency amplitude, the former cannot be easily discriminated from the latter. Therefore, the peak at the fault frequency is hidden in the shadow of the main frequency component, hence the fault will not be detectable. As a solution to vanish the base frequency component, a method based on the Algebraic Identity of trinomial expansion is proposed in this paper which enables us to display the difference between the frequency of the fault signature and the base frequency. In this article, the fault of the broken rotor bars of the squirrel cage induction motor is revealed by the proposed method. In addition, a frequency weighting technique is presented to magnify the component at the fault related frequency compared to the lower frequencies. To validate the proposed methods, they are examined on the laboratory data obtained from three different operating conditions including the direct online start, the direct torque control, and the scalar control and the results show the ability of the proposed methods in fault detection of an induction motor.