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DoctorKnow® Application Paper

Title: Vibration Problems Associated with Two Pole, Alternating

Current Motors
Source/ Don Taft
Author:
Product: General
Technolog Motor
y:
Classificat Not Classified
ion:

VIBRATION PROBLEMS ASSOCIATED WITH TWO POLE,

ALTERNATING CURRENT MOTORS

by

Don Taft
Plant Superintendent R.A. Reed Electric Co.
Los Angeles, California

ABSTRACT

Recently there has been much concern over vibration levels at the 120 hertz
frequency band on large two pole electric motors. Much of the cause for this
vibration is inherent to motor design the difficulty being in building an electro-
mechanical device that turns at the same frequency as the electrical forces
that drive it. Eccentricities, no matter how slight, excite the ever present
electrical/magnetic frequencies making designing these units difficult at best.
Tolerances must be held tightly without making the unit economically
unattainable. On many occasions this problem does not manifest itself until
the unit has been overhauled. It is the intent of this paper to give the reader
a better understanding of the cause for this phenomena and suggest
possible solutions for amplitude reduction.

OVERVIEW

Being from a large repair facility I have had the opportunity to take spectral
data on literally hundreds of motors. The large two pole units, however,
proved to be the most interesting and the source of most controversy
regarding our ability as motor repair experts, it is these units that are to be
studied. Twenty sample motors were selected to study, however only the
three most interesting cases will be presented. Sample motors were of
varying size and make. Because I was primarily concerned with electrical
frequencies I chose only sleeve bearing motors this eliminated unwanted
anti-friction bearing noise. Terminology and basic construction will be first
then we will go into the different design types and their purpose, case
studies are next and we will finish up with setting acceptable standards for
re-builders and manufacturers.
BASIC MOTOR CONSTRUCTION

All of our case studies were standard induction motors which consist of a
rotor assembly , stator assembly, end-brackets, sleeve bearings, oil rings
and a variety of enclosures and cooling fans.

Stator - An assembled unit consisting of a pressed and welded stack of

stamped or laser cut, slotted, steel plates anywhere from .020" to .040" in
thickness called laminations. The pressed stack is called the core. Insulation
and a winding are installed in this core to complete the stator assembly.

Rotor - A stack of similar laminations pressed onto a shaft in which rotor

bars are cast (called a cast rotor) or pressed (called a fabricated rotor) into
the slots formed into the rotor stack.

BASIC MOTOR CONSTRUCTION

Bearing - All motors referred to in this paper are babbitt sleeve bearings
consisting of a brass or cast iron shell with a poured babbitt lining that is
machine bored for a standard clearance to the shaft journal. Some of the
units tested had split bearings, however bearing to shaft tolerances are the
same and have no effect on test results.

Housing - The bearing support which is registered to the stator assembly to

align the rotor in the stator bore. All sample motors have sump type
housings which provide an oil reservoir directly beneath the bearing
assembly.

Oil Ring- A brass ring which hangs on the bearing journal through a slot in
the bearing assembly and hangs into the oil sump. When the shaft turns the
ring dips into the reservoir bringing oil back up to the journal surface.

MOST COMMON CAUSES OF 120 HERTZ VIBRATION

Twenty motors which exhibited high levels of vibration at the 120 hertz
frequency band were tested before and after repair. Although some motors
had more than one problem the most predominant cause is listed.

Primary Cause Number of Units Effected

Internal Misalignment 9
Loose Stator Core/Laminations 4
Rotor or Cage Thermal Bow 3
Uneven Feet/Base Forcing Internal Misalign. 2
Cracked Shaft 1
Broken Rotor Bar 1

INTERNAL MISALIGNMENT

This is the most common cause for 120 hertz vibration that we have found,
in fact it is has become standard procedure for Reed Electric to measure
and record the air gap on these motors before and after repair. It is
important to remember that there are many causes of internal misalignment
most of which are caused by poor repair procedures. This is the reason why
the problem is so prevalent after a unit has been sent to a repair facility.
The best indicator of good internal alignment is the air gap measurement.
Some manufacturers had the foresight to install access holes in the bearing
housings for checking air gap with the unit completely assembled.

ROTOR / GAGE THERMAL BOW

All motors tested had what are considered, by definition, a flexible rotor
design which means that the full load RPM is above the REED critical
frequency or resonant frequency, but this does not mean that the rotor
actually flexes. Or does it? There are at least three different metals that
make up a modern rotor. Manufacturers in their quest for more efficient, less
expensive motors have chose to reduce rotor diameter and increase their
length because of the different expansion coefficients involved the rotors can
and do change under load and varying thermal conditions. Bar to slot fit and
core to shaft fit must allow for this expansion, the manufacturers design
these rotors for particular metals and the changing of rotor bar material or
even shaft material is not recommended.

Not all bowing problems are design flaws in fact most are from external
causes. Frequent starting or starting under excessive load can cause a
temperature differential by heating the rotor bars unequally through
induction. Hot spots on the rotor or stator causing uneven thermal
expansion. Poor shaft to core fit, too tight axial growth is limited, too loose
and it is subject to magnetic pullover.

UNEVEN FEET / BASE FORCING INTERNAL MISALIGNMENT

Most motors have mounting pads or feet which are used to fasten the motor
to it's base. These feet are, in most motors, an intricate part of the stator
assembly. If the feet or the base that they bolt to is uneven then by
tightening the hold down bolts the stator can become distorted causing an
uneven air gap. This is one of the easier problems to troubleshoot in the
field. By using your CSI analyzer in monitor mode you can loosen the feet
one at a time while observing the 120 hertz peak. This problem can
sometimes be identified using a soft foot test or by the use of feeler gauges,
however on many occasions such as an angular soft foot or tweaked base
using the analyzer is much faster and far more accurate.

Again repair shops can cause a stator frame to warp if they do not have a
method of controlling burn temperature.
INTERNAL MISALIGNMENT

However in most cases the top half of the housing must be removed
allowing access to only three points and in some cases the housings are a
one piece construction which leaves only time consuming and tedious
mechanical measurements. Most manufacturers specify no more than a ten
percent deviation of half the total air gap.

d = .1 ( .5 x ag )

d = Allowable air gap differential

ag = Total air gap

So a measured air gaps of .035 TDC .032 at 90 degrees and .028 at 270
degrees would not be acceptable as vertically misaligned.

LOOSE STATOR CORE / LAMINATIONS

This problem commonly occurs in motors that have been rewound primarily
due to lack of temperature control during the burn cycle causing the
laminations to distort and also breaking down the fine coating on the
lamination plates. Another common cause for this problem occurs when the
burnt winding is pulled from the slots in a sloppy manner causing the teeth to
bend or mushroom. Other problems related to the burn process are stator
shell or support warpage and case expansion.

This problem may not be detected with an air gap check and if not caught by
the repair facility before assembly can cause endless hours of frustration.

There is also a phenomena known as lamination arcing. This is caused by

eddy currents in shorted plate teeth causing electrical arcing and with it 120
hertz vibration, It also creates hot spots and flux deflection fields which in
turn can cause rotor thermal bow.

CRACKED SHAFT - BROKEN ROTOR BAR

These problems cause similar results so they have been consolidated.
There has been an abundance of papers, articles and studies on
identification of broken rotor bars, however the problem of broken or cracked
rotor bars occur in less than one half of one percent of the motors we test.
Cracked shafts are-even less common and are usually caused by
mechanical or thermal stress. Rotor bar detection is still an important tool in
troubleshooting elect, electrical problems and
should always be identified by the analyst if a rotor is being forced off it's
magnetic center a definite increase becomes apparent at bar pass
frequency. Other possible causes for increased rotor bar vibration are loose
bars, eccentric rotor, weakened end-ring and unbalanced current.

CASE #1

Reliance: 400HP, 2:Pole, 2300VAC, Fr.501Oz. Mod. 2XXQ11830 Cast Iron,

TEFC, Exp. Prf.

Complaint: New motor did not meet customer vibration standards for 120
hertz amplitude of .03 In/Sec.

Initial test at full voltage showed a predominant peak at 120 hertz. Units
rotor was tested by the single phase method and determined to be good.
The winding was then surge tested and also found good. Other standard
testing was acceptable and the unit was then dismantled. Because this unit
had one piece bearing brackets we had to verify air gap by mechanical
measurements and checking rotor run-outs and register fits.
It was determined that the sleeve bearing register was cut off center
by .0075". A new bearing and housing were installed solving the problem.

CASE #2

Siemens-Allis: 17§0HP, 2 Pole, 4160VAC, Fr. 6810, Mod. 125 Steel, WPII.

Complaint: Ever since motor had been rewound the unit had developed a
noticeable vibration. Subsequent testing by analyst indicated an electrical
fault and motor was sent to us to try and determine the cause.

This unit was a split case design with the stator assembly fastened to the
bottom half of the case with eight 1.250" bolts and steel shims between the
stator and case.

The air gap measurement was easy to attain and showed the stator was
sitting at a twelve degree incline. The proper shims were installed and the
units vibration was reduced by over sixty percent.
TEAMWORK FOR TEN - SUGGESTIONS FOR A WORKING
RELATIONSHIP

In keeping with the spirit of this years conference here are some
suggestions to help you establish a good working relationship with repair
facilities as well as motor manufacturers. With the advanced equipment in
your possession you can set realistic standards for acceptability saving your
company time and money. Also by letting your vendors know of your
standards they can save the wasted effort of trying to sell you something you
don't want.

RE-BUILDERS

* Establish repair standards for each type of motor at your facility. You can
use many different sources for setting these standards some of which are
EASA, IEEE, API, NEMA and even your competition. Your motor shop
should be able to assist you in acquiring these publications. Tour Facility.

* Insist on copies of all test results including air gap measurements.

* Ask for rotor bar and stator slot count also any bearing numbers and make.

* Have motor feet checked for flatness and record amount of any soft feet.

* On large motors ask for shaft voltage and current test results.

* On large motors you should always invest the time to witness final test run.
Make sure that full voltage is applied and unit is bolted down.

* Make sure that bearing temperatures stabilize and are balanced.

* If unit requires rewinding insist that exact, factory winding data is used.

* Make certain that proper stripping procedures are used and that ovens are
equipped with temperature l imitation, core should never reach a
temperature above 660 degrees.

* Get core loss test results before and after burn.

* If any machine work is required insist on approving all materials and

procedures. Again, use factory tolerances on all fits.

* Have results of final balance recorded.

MANUFACTURERS

Many times your input on new motor purchases is limited by national

contracts or low bid policies, however on the larger motor purchases
technical as well as financial audits are in order. An apparent savings could
cost your company tens of thousands of dollars in lost production if technical
standards are not maintained.

* Set acceptance standards for all new motor purchases using previously
mentioned method.

* Ask for manufacturers written quality standards.

* Try to get as much engineering data as possible for future reference. At

minimum make them give you the rotor bar and stator slot count and
useable bearing numbers.

* Request to witness test run and bring your analyzer to verify conformance
to your standards.

BIBLIOGRAPHY

1. Electric Motor Repair, Robert Rosenberg Holt, Rinehart, Winston - Long

Beach, New York

2. The Simplified Handbook of Vibration Analysis, Arthur R. Crawford

Computational Systems Inc. - Knoxville, TN

3. Rotor Failures in Squirrel Cage Induction Motors, Austin H. Bonnett,

George C. Soukup U.S. Electrical Motors - Prescott, AZ Paper No. PCIC-85-
24, IEEE
 4. Analysis of Rotor Failures in Squirrel Cage Induction Motors, Austin H.
Bonnett, George C. Soukup U.S. Electrical Motors-Prescott, AZ Paper No.
PCIC-87-2, IEEE

5. Physics for Technical Students - Mechanics and Heat, William Ballantyne

Anderson, Ph.D. McGraw-Hill - New York, NY

6. EASA - Technical Manual Electrical Apparatus Service Association - St.

Louis, MI

7. NEMA - Motors and Generators, MG 1 National Electric Manufacturers

Association - Washington, D.C.

8. Electric Motor Repair Shop Problems and Solutions, Samuel Heller, P.E.
Datarule Publishing Co., Inc. - New Canaan, CT

9. Induction Motor Electrical Noise and Vibration and Case Problems, Cletus
A. Corey MagneTek - Louis Allis

10. Some Aspects of Magnetic Centering Effects on Sleeve Bearing

Induction Motors, Bob Brozek, M.E.E. EASA - Tech Note No. 15 Electrical
Apparatus Repair Association, St. Louis, MI

11. Induction Motor Magnetic Vibration, J. Howard Maxwell Arizona Public

Service Co. - Palo Verde Nuclear Generating Station - Phoenix, AZ

12. Winding Alternating - Current Machines, Michael Liwschitz-Garik, Dr-

Ing., Asst. Celso Gentilini,B.E.E. D. Van Nostrand Co., Inc. - New York, NY

All contents copyright © 1998 - 2006, Computational Systems, Inc.

All Rights Reserved.

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