Application of Online Voltage Mismatch Condition
Monitoring of Induction Motor Stator Windings in a
Mining Environment
J. Sottile F. C. Trutt
230 MMRB 687B AH
University of Kentucky University of Kentucky
Lexington, KY 40506-0107 USA Lexington, KY 40506-0046 USA
jsottile@ieee.org ftrutt@ieee.org
Abstract - Previous theoretical and laboratory research has
demonstrated the utility of using voltage mismatch predictors for
online condition monitoring of induction motor stator windings.
However, the use of this monitoring system in a mining or other
industry application depends upon the ability to determine motor
impedance parameters prior to the onset of winding
deterioration. Since these impedance parameters depend upon
the motor speed, such evaluations require the collection of
voltage and current data over a range of operating speeds. In
addition, a sufficient amount of natural or created voltage
unbalance is required in order to evaluate these parameters. The
investigation presented in this paper uses duplicate data-
collection and evaluation setups in both an operating mine and in
the laboratory in order to obtain a better understanding of the
voltage variations that are required for determination of the
motor impedance parameters. Results are then related to the
feasibility of applying voltage mismatch condition-monitoring
procedures in an operating mine.
Keywords induction motor, condition monitoring
I. INTRODUCTION
Previous research has demonstrated that the monitoring of
electrical parameters can be a useful technique for the
condition monitoring of induction motor windings [1-14]. As
part of this work, an approach utilizing voltage mismatch
comparison to detect stator winding deterioration or faults in
operating induction motors has been proposed and verified in
the laboratory [13, 14]. Application of this voltage mismatch
comparison technique requires measurement of the three-phase
voltages, three-phase currents, and motor speed. In the
evaluation process, positive- and negative-sequence voltage
values computed from the measured line voltages are compared
with positive- and negative-sequence voltages computed from
measured currents and speed-dependent impedance parameters.
Prior to implementation, a training process is necessary to
establish the impedance parameters. This process requires that
two independent sets of voltage and current measurements be
recorded at the same motor speed. Because these terms are
speed dependent, this process must be repeated for different
motor operating speeds. In the laboratory, this process can be
conducted very conveniently. A specified supply unbalance for
the motor can be established, for example, by inserting an
0-7803-7883-0/03/$17.00 2003 IEEE
1637
J. L. Kohler
National Institute for Occupational
Safety and Health
Pittsburgh, PA 15236 USA
jtk4@cdc.gov
external resistance in one of the lines, and the motor load can
be varied by suitable means and the voltages and currents can
be recorded. Next, the external resistance can be inserted in
another line and the process can be repeated. In a field
application, the training process cannot be controlled in the
same fashion as in the laboratory. It may be impractical or
impossible to insert an external resistance in the lines to create
the necessary voltage unbalance. Motor speed will be a
function of the application and cannot be controlled, and in
come cases, measuring motor speed may be problematic.
The investigation presented in this paper addresses the
issues associated with establishing the impedance matrix in an
industrial setting. We begin with a brief description of the
voltage mismatch detectors. Subsequently, a description of the
laboratory and field efforts is presented, followed by the results
of these studies and plans for future work.
II. BACKGROUND
A. Voltage Mismatch Detectors
A brief description of the voltage mismatch detectors is
presented here. Additional details can be found in [13, 14].
Consider a three-phase, wye-connected induction motor
connected to a three-phase, solidly grounded wye-connected
power source. (If the power source or motor is in a delta
configuration, it is assumed that this component is represented
by its equivalent wye.)
Define V'a0, Va1, and Va2 as the phase a zero, positive, and
negative sequence symmetrical components of the source
voltages measured with respect to ground. Similarly, we define
Ia0, Ia1, and Ia2 as the symmetrical components of the line
currents and Va0, Va1, and Va2 as the symmetrical components
of the motor voltages measured with respect to the junction
point of its wye connection. The zero sequence voltages V'a0
and Va0 differ by the voltage at the junction point of the motor
wye connection measured with respect to the ground reference
while the corresponding positive and negative sequence power
source and motor phase voltages are equal.
From a standard text, it may be shown that [15]
Va0 = z00 Ia0 + z01 Ia1 + z02 Ia2, (1)

Va1 = z10 Ia0 + z11 Ia1 + z12 Ia2, and (2)
Va2 = z20 Ia0 + z21 Ia1 + z22 Ia2. (3)
where the zxy parameters are functions of the motor design,
construction, any internal deterioration, and the operating
speed. The zero sequence component of the line currents, Ia0,
is approximately zero if there is no ground fault in the system.
Because such faults or deterioration involving ground may be
detected by standard techniques that monitor the zero-
sequence component of the line currents and are relatively
easy to detect, we will concentrate on situations in which there
is no ground fault present, i.e., Ia0 is assumed to be zero.
With this assumption, (2) and (3) become
Va1 = z11 Ia1 + z12 Ia2, and (4)
Va2 = z21 Ia1 + z22 Ia2. (5)
The impedance terms z11, z12, z21, and z22 can be determined
using recorded lines voltages and currents from two separate
tests on a motor running at any given speed. If these tests are
repeated at different motor speeds, a library of zxy parameters
may be determined over a range of motor operating speeds.
Once these impedance parameters have been determined, it
becomes possible to monitor the line voltages and line currents
from which Va1, Va2, Ia1, and Ia2 may be calculated. Equations
(4) and (5) may then be used to calculate Va1 and Va2 at the
measured motor operating speed and if no internal
deterioration has occurred, Va1 and Va2 calculated from the
measured currents and impedance values should match the Va1
and Va2 values extracted from the measured voltages. If
internal deterioration such as a turn-to-turn fault or phase-to-
phase leakage has developed, the zxy parameters will have
changed from their normal values at that speed and there will
be a mismatch between the two sets of voltages. This
mismatch may then be used as an indicator of internal motor
deterioration.
An important advantage is that this condition monitoring
approach has been shown to be independent of initial
construction imperfections and unbalances within the motor
itself as well as changes or unbalanced conditions that may
develop in the motor power supply system [14]. In addition,
performance should not be affected by mismatched sensors;
therefore, no careful sensor calibration is necessary. However,
it is assumed that the sensors will not be rearranged or
replaced during both training and condition monitoring
processes.
B. Determination of the Impedance Matrix
The calculation of the impedance matrix is a
straightforward process. However, because two independent
sets of voltage and current measurements are required to
compute the impedance parameters at a given speed, it is
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necessary that the two tests be conducted under different values
of voltage supply unbalance. Using small motors in the
laboratory, these conditions are not difficult to establish. An
autotransformer or resistor can be used to create the necessary
unbalance and the speed can be controlled by connecting the
motor to a generator and varying the generator load in
sufficiently small increments.
However, in an industrial setting, it may be impractical to
attempt to control the voltage supply and motor speed in a
similar fashion. To be accepted by the mining or other
industry, the training and monitoring processes should not
impact the operation (other than the installation of sensors).
Therefore, a more practical approach for an industrial setting is
to allow the motor to operate normally and to collect training
data over a period of time. During this data collection process,
there should be sufficient natural variations in the voltage
supply to develop the impedance parameters over the range of
observed operating speeds. It is worth noting here that voltage
unbalances, which are necessary for determination of the motor
impedance parameters during the training phase, are of no
consequence during the subsequent condition monitoring
process.
III. LABORATORY INVESTIGATION
In order to experimentally investigate the sensitivity of
induction motor impedance parameter determination to the
degree of voltage unbalance and possible experimental error, a
laboratory setup was constructed using instrumentation
identical to that which was installed in an operating mine. The
three line currents were measured with 200:1 current
transformers and burden resistors were used to convert the
current to a voltage signal. The three line voltages were
measured with three 480:2.84V potential transformers. Speed
was measured with an optical tachometer. The tachometer had
a 0-5 V analog output that was programmable over a user-
defined speed range. The machine used in this laboratory
investigation was a 208-V, 2.0-kVA, two-pole universal
laboratory machine (ULM) connected as an induction motor.
This motor was coupled to a dc generator whose output was
connected to a bank of resistors that could be switched in
300W increments. A rheostat was placed in the generator field
circuit to control output voltage and provide finer loading
increments. The voltage, current, and speed measurements
were fed into an analog to digital converter and then into a
computer for analysis. Each data set consisted of seven
channels of input (three voltage, three current, and one speed)
consisting of 4096 points per channel sampled at a rate of
4098.4 samples per second. This provided a resolution of
approximately one Hertz in the frequency domain.
The first series of laboratory tests was conducted with the
ULM running as an induction motor with a wye-connected
stator winding. In order to produce a voltage unbalance, a 3
resistor (i.e., a dc resistance of 3 at room temperature) was
placed in line A for one series of tests, and line B for the next
series of tests. This produced a voltage unbalance factor,
defined as the ratio of the negative sequence voltage to the
positive sequence voltage, of approximately 2.5%. The ULM
was run at 3350 rpm with a balanced voltage supply for 30
minutes to allow it to reach a steady operating temperature.
Tests were conducted immediately after the warm-up period.
Motor speed was varied from 3350 rpm to 3495 rpm in 5-rpm
increments (to the extent possible). The entire series of tests
took less than one hour to conduct, and no noticeable
additional heating due to the unbalance was noticed, although
some heating probably did occur.
The graphs given in Figs. 1-4 show the four terms of the
impedance matrix for the speed range tested. Because of the
large differences in scale, they have been shown on separate
graphs to make it easier to observe changes in the values.
Three of the impedance values, z11, z21, and z22 have very
consistent behavior; z11 increases with decreasing load, as
expected; z22 is nearly constant, as expected; and z21 shows a
very gradual increase.
Unfortunately, z12 is poorly behaved. The reason for this
becomes evident if Cramers Rule is applied to the set of Figure 2. Real and imaginary components of z12 as a function of speed
equations that are used to calculate z11 and z12. When this is for the ULM.
done, the value of the numerator when determining z12 is the
difference between two large, nearly equal numbers, Ia1Va1 The second series of laboratory tests was designed to
and Ia1Va1. (Unprimed and primed values are used to investigate the effects of voltage unbalance difference between
distinguish the two data sets that are used in the determination a pair of measurements on the calculated value of the motor
of the impedance matrix.) Thus any small measurement error impedance parameters. For these tests, the motor speed was
will cause a large change in the very small value of z12 leading maintained at 3425 rpm and a voltage unbalance difference,
to instability in this calculation. (Recall that in a perfectly VUD, was defined as the magnitude of the quantity
balanced system, the off-diagonal terms would be equal to
V a 2 V a' 2
zero; in a typical system, they should be close to zero.) It VUD = ( 6)
therefore seems clear that this impedance cannot be used in a V a1 V a'1
practical system where some measurement inaccuracies must in percent. The value of the resistance inserted in line A or B
be expected. Fortunately, the dominance of z11 is such that no was varied such that the magnitude of this voltage unbalance
significant error should be introduced if z12 is assumed to be difference assumed values between 3.5% and 0.2%. The
small compared to z11 when determining the remaining motor lowest value of 0.2% was limited by the natural unbalance that
impedances and the voltage mismatches. existed in the laboratory supply system.

Figure 1. Real and imaginary components of z11 as a function of speed Figure 3. Real and imaginary components of z21 as a function of speed
for the ULM. for the ULM.

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 Figure 4. Real and imaginary components of z22 as a function of speed
for the ULM.
Results of these tests are shown in the graphs of Figs. 5
7. In each of these graphs, the real and imaginary parts of an
impedance parameter are plotted as a function of the
magnitude of the voltage unbalance difference. The dual plots
contained in Fig. 5 show the value of z11 calculated with z12
included (solid lines) and with z12 assumed to be equal to zero
(dashed lines). (Data point markers were left off of this figure
to show these differences more clearly.) In this latter case, the
average value of z11 for the pair of measurements was utilized.
These results clearly show an increase in the variability of
the calculated values of z21 and z22 as the magnitude of the
voltage unbalance difference goes below approximately 1%.
However, when z12 is assumed to be zero, z11 = 30.6 + j14.7
Figure 5. Real and imaginary components of z11 as a function of
voltage unbalance difference for the ULM operating at 3425 rpm.
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Figure 6. Real and imaginary components of z21 as a function of
voltage unbalance difference for the ULM operating at 3425 rpm.
Ohms is essentially constant down to the lower limit of the
experiment. If average values for the other impedance
parameters are calculated, z21 = 0.0985 + j0.147 Ohms and z22
= 1.87 + j2.81 Ohms. If only measurements where the
magnitude of the voltage unbalance is below 1% (where the
variations in the calculated impedance values are the greatest),
the average values become z21 = 0.0978 + j0.149 Ohms and z22
= 1.86 +j 2.825 Ohms. It therefore appears that average values
for the motor impedance parameters may give useable results,
if a sufficient number of measurements are obtained, even if
some low values of unbalance difference contribute to
variations in the individual computations.
Figure 7. Real and imaginary components of z22 as a function of
voltage unbalance difference for the ULM operating at 3425 rpm.
 IV. FIELD INVESTIGATION

A. Training Procedure
During the field effort, data files were collected at an
underground limestone mine using a system that was identical
to the one used in the laboratory. This allowed for a
comparison of the quality of data between laboratory and the
operating mine and also provided an opportunity to debug the
data collection system in the laboratory if problems were
encountered in the mine. The motor selected for the study was
a 150 hp conveyor belt drive motor that transported rock from
the mines primary crusher. The potential transformers and
current transformers were located at the secondary of a
12,470:480V transformer that supplied the motor and crusher.
The data acquisition system was set up approximately six feet
from the transformer enclosure. The conveyor motor was
located approximately 200 feet from the transformer, and
required 230 feet of signal wire to reach the data collection
system. Figure 8 shows the motor and the optical speed
(a) Laboratory speed signal.
sensor.
A total of 120 files were collected over a three week
period, using the same sampling parameters as those used in
the laboratory. The observed voltage unbalance factor was
less than 0.5% for all of the files recorded. During the data
collection process, it was observed that the motor operating
speed was relatively narrow, ranging from 1787 to 1798 rpm,
indicating that this motor was probably oversized for this
application. We also observed that the tachometer signal had
significantly more noise than the signal recorded in the
laboratory, as illustrated in Figure 9. This was problematic
because the z11 impedance parameter is very sensitive to
changes in speed. During these tests, the magnitude of the
zero-sequence current was monitored and was less than 0.3 A,
justifying the assumption of (4) and (5).
An algorithm was developed in which pairs of files were
matched to compute the impedance parameters. Because of
the uncertainty in the speed measurements, files were matched
primarily on the basis of positive sequence impedance, and the (b) Mine-site speed signal.
speed was computed as the average of the two measurements.
Figure 9. Sample of tachometer speed signals.

The second criterion was that the voltage unbalance be

Figure 8. Conveyor motor and optical speed sensor.
different to insure independent equations were used in the
calculations. Of the 120 data files collected during the
training process, 27 combinations were initially selected as
meeting the criteria. Of the 27 files initially selected, 23
provided useable information for determining the impedance
parameters. While the algorithms for selecting useable
combinations of data files were applied by hand in this case,
programming techniques may be utilized to automatically
incorporate these decisions into an automated system.
Figures 10 through 12 show the results of the impedance
matrix training process for the data collected at the mine site. It
is noted here that these values were determined from an
average voltage unbalance factor of less than 0.5%. As a
result, the values are more widely scattered than those collected

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 Real
Imaginary
Figure 10. Real and imaginary components of z11 as a function of
speed for the 150hp conveyor motor.
in the laboratory at higher levels of unbalance; however, clear
trends were still established. Another difference is that z21 of
the conveyor was approximately constant while z21 for the
ULM exhibited a slight increase with increasing speed.
B. Condition Monitoring
Once the impedance parameters were determined, a
simulated health-monitoring procedure was conducted. This
procedure consisted of randomly selecting 15 files (that were
not used in the training process) over the measured speed range
and computing the positive and negative sequence voltage
mismatches. Because these files were collected during the
same time period as those used for training, the mismatch
values should be small and representative of what would be
expected for condition monitoring of a healthy motor.
Real
Imaginary
Figure 11. Real and imaginary components of z21 as a function of speed
for the 150hp conveyor motor.
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Real
Imaginary
Figure 12. Real and imaginary components of z22 as a function of
speed for the 150hp conveyor motor.
Figure 13 illustrates the results of this process. The
mismatch values are the magnitudes of the vector difference
between the calculated and measured voltage values. Figure 13
(a) shows that the positive sequence voltage mismatch is less
than 12 V in all cases, with a mean value of 6.7 V. These
values represent 4.33% and 2.42%, respectively, of the rated
line-to-neutral voltage of this motor. The plot also shows that
the mismatches are fairly uniform over the measured speed
range. This result is encouraging because of the sensitivity of
z11 to speed, especially near synchronous speed. Figure 13 (b)
shows the negative sequence voltage mismatch values are all
less than 0.5 V with a mean mismatch value of 0.27 V.
Although these mismatches are much smaller than their
positive sequence counterparts, they represent a larger fraction
of the measured negative sequence voltage compared with the
positive sequence values. For example, the average measured
negative sequence voltage was approximately 1.2 V, so the
average mismatch is approximately 23% of the average
observed negative sequence voltage. This is expected because
the negative sequence values are much smaller than the
positive sequence values and are more difficult to measure
accurately.
Because it is not possible to simulate motor deterioration in
this setting and there was no apparent deterioration or failure
that occurred during the monitoring period, it was not possible
to predict the magnitude of the change in the mismatch
predictors with deterioration as compared to random variations
for the healthy motor. However, some insight into expected
performance can be obtained by comparing these results with
results of simulated deterioration tests previously conducted on
the ULM. Fig. 14 is a repeat of Fig. 2 in [14] showing the
change in the voltage mismatch detectors with increasing
deterioration current for healthy operation and for increasing
levels of simulated deterioration. In this figure, we observe a
non-deteriorated Va1 mismatch of approximately 2.0 V or
approximately 1.75% of the rated line-to-neutral voltage
compared with the mine site mean of 6.7 V (2.42% of rated)
and maximum value of 12 V (4.33% of rated). The ULM non-
deteriorated Va2 mismatch is approximately 0.2 V compared

(a) Positive sequence voltage mismatch.
(b) Negative sequence voltage mismatch.
Figure 13. Positive and negative sequence voltage mismatch values for
the 150 hp conveyor motor.
with the mine site mean and maximum mismatch values of
0.27 V and 0.5 V, respectively.
These comparisons indicate that the field site results for the
healthy motor are similar to the laboratory study previously
conducted, although the non-deteriorated mismatches are
somewhat larger. It is anticipated that other industrial sites
would exhibit similar results. These results also indicate the
need for using trends in the mismatch values rather than simply
establishing a threshold value. A major point of interest from
Figure 14 is that in percentage terms, the maximum positive
and negative sequence voltage mismatches observed for the
healthy motor in the mine tests are exceeded in the ULM when
the deterioration current is limited to approximately 5% of the
short circuit value. This is a very low level of deterioration,
and at this, as well as higher simulated levels of deterioration,
no abnormal operation of the ULM was observed.
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25
Voltage Unbalance = 5.2%
n = 3303 rpm
20 Ia2 Measured x 10
Voltage (V) or Cuttent (A)
Ia2 Calculated x 10
15
Va2 Mismatch Calculated x 10
Va2 Mismatch Measured x 10
10
5
Va1 Mismatch Measured
Va1 Mismatch Calculated
0
0 2 4 6 8 10 12 14 16
Deterioration Current (Percent of simulated short-circuit value)
Figure 14. Experimental and theoretical voltage mismatches with a
large supply voltage unbalance for the ULM [14].
C. Implementation Issues
The objectives of this study were to obtain a better
understanding of the voltage variations that are required to
develop the motor impedance parameters, and to establish
whether it is feasible to conduct this process in an industrial
setting.
The results of the field study are encouraging, especially
when considering the conditions under which they were
conducted. For example, the data collection process was
conducted manually, in which an operator sat at the data
collection system and triggered the acquisition process. This
was appropriate for this study because it allowed the operator
to monitor the data collection process and deal with any
unforeseen problems. However, compared with an automated
system, it limited the number of opportunities for collecting
files in which the voltage unbalance difference is large enough
to establish the impedance parameters with a high degree of
accuracy. When fully implemented, an automated process
could be conducted almost continuously over several weeks
thereby providing better estimates of the impedance
parameters.
Another difficulty that is more problematic in an industrial
application is the determination of motor speed. For this study,
an optical tachometer was used because it was accurate,
convenient to use, and it worked well in the laboratory.
However, in the mine environment, the tachometer signal was
noisy, making it difficult to accurately measure motor speed.
This hampered the determination of the impedance parameters
because pairs of files had to be matched primarily on the basis
of positive sequence impedance and the speed was determined
by averaging the values of two files. It is expected that similar
noise problems would be encountered at other locations, or that
it may simply be impractical to mount a tachometer.
There are alternatives to using a tachometer for measuring
speed. One technique is to obtain the motor running speed
from analysis of the amplitude spectrum of the line current.
However, this approach requires a relatively long record length
(approximately 30-50 seconds) to obtain sufficient resolution in
the frequency domain for an accurate speed determination. In
this application, and many mining applications, the motor load
and speed may vary during this length of time such that it
would be necessary to implement training and monitoring
algorithms based on average values observed during the
sampling interval.
Plans for future work include the investigation of more
reliable and unobtrusive methods for accurately measuring
motor speed; the use of longer sampling intervals and the
application of averaging techniques; the development and
testing of an automated system for the training and health
monitoring processes; and installation of several prototype
systems at industrial sites. These systems would then be used
to carry out the training process and conduct condition
monitoring for an extended period of time.
V. CONCLUSION
The results of the training and monitoring processes for the
voltage mismatch detectors are very encouraging. Laboratory
tests have indicated that training can be conducted at fairly low
levels of voltage unbalance, provided enough samples are used
to help reduce random error. Based on these results, a field
study was conducted at an underground limestone mine in
which the training process was conducted without the benefit
of an artificially induced supply unbalance or control of the
motor speed. This process was successful despite its being
hampered by noisy signals from the optical tachometer used to
obtain the motor speed and relatively small natural supply
unbalances. Subsequently, a simulated health monitoring
process using randomly selected sets of mine data showed that
reasonably small voltage mismatch values were observed for
the healthy motor, i.e., less than 4.33% of rated voltage for the
positive sequence mismatch and less than 0.5 V for the
negative sequence mismatch. These mismatches indicate that
the computed impedance parameters are fairly representative of
the motor. Further comparison of this mine data with
laboratory observations showed that normal mismatches in the
mine data were exceeded at low levels of simulated stator
winding deterioration. As a result, it appears that voltage
mismatch condition monitoring could provide useful early
warning information in this industrial setting.
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