This article has been accepted for publication in IEEE Access.

This is the author's version which has not been fully edited and
content may change prior to final publication. Citation information: DOI 10.1109/ACCESS.2022.3232063

Date of publication xxxx 00, 0000, date of current version xxxx 00, 0000.
Digital Object Identifier 10.1109/ACCESS.2017.DOI

Digital Twin-based Monitoring System of

Induction Motors using IoT Sensors and
Thermo-Magnetic Finite Element
Analysis
JHENNIFER F. SANTOS 1 , BENDICT K. TSHOOMBE 1 , LUCAS H. B. SANTOS 1 , RAMON
C. F. ARAÚJO 2 , ALLAN R. A. MANITO 3 , WELLINGTON S. FONSECA 2,3 , MARCELO O.
SILVA 2
1
Department of Electrical Engineering, Federal University of Pará, Belém 66075-110, Brazil
2
Mechanical Engineering Graduate Program, Federal University of Pará, Belém 66075-110, Brazil
3
Electrical Engineering Graduate Program, Federal University of Pará, Belém 66075-110, Brazil
Corresponding author: Ramon C. F. Araújo (e-mail: [email protected]).

ABSTRACT Electric induction motors are the type of motor most commonly operated in industry, and
for this reason technologies that predict faults and reduce the corrective maintenance are of great interest.
In this context, this paper presents a predictive maintenance tool of electric motors using the concepts
of Digital Twin (DT) and Industrial Internet of Things (IIoT). The proposed system is innovative, as it
monitors the motor current and temperature by means of sensors and a low-cost acquisition module, and
these measurements are sent via Wi-Fi to a database. The concept of DT was leveraged by providing the
measurements as inputs to a high-fidelity strongly-coupled model of the monitored monitor, using the
Finite Element Method (FEM). The results obtained are satisfactory, because the sensors used presented
acceptable errors that do not interfere with the reliability of the results. The computer simulation showed
relative errors below 4% in the conductivity analysis and 10% in the temperature analysis. In addition, the
simulation allows verifying the internal temperature of the motor, its resistive losses, and the intensity of
the magnetic flux at each pole. It is worth pointing out that the internal analysis performed is only possible
due to the combination of IIoT and computer simulations. Therefore, they allow a better diagnosis of the
motor’s operational status and also a time estimate for the next maintenance service, thus being ideal for the
industrial sector.

INDEX TERMS Condition monitoring, digital twin, finite element analysis, induction motors, internet of
things.

I. INTRODUCTION Failures represent large financial and operational losses due

LECTRIC machines play a key role in modern society,
E especially in industrial operations. Used as the driving
force for pumps, fans, compressors, conveyor belts, electric
to unplanned corrective repairs and production downtime
[6]. Therefore, great attention is paid to the maintenance of
induction motors.
vehicles and other devices, electric machines are responsible In recent years, the industry has been adopting the predic-
for consuming 50% of the total energy generated worldwide tive maintenance approach, also called condition monitoring.
[1], [2]. Among these machines, the induction motor is the In this paradigm, shutdowns for manual inspection and re-
most widely used in industry [3]. pairs are performed with optimal periodicity, based on the
Like any other electromechanical device, induction motors actual current state of the equipment [7], [8]. In this way,
are subjected to mechanical stress (e.g., vibration), thermal outages are scarce when the equipment is in good working
(heat) and electromagnetic stresses during operation [4], [5]. condition, and become more frequent in the end of its life
In the absence of proper maintenance, the motor progres- cycle.
sively wears out and, eventually, a disruptive failure occurs. Predictive maintenance requires continuous monitoring of

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the equipment with sensors, in order to estimate its actual Digital Twin model. The use of IoT and DT for monitoring
state [9]. In this context, the technology of monitoring sys- is promising because it allows predictive maintenance to be
tems has been positively affected by the emerging concepts applied to a variety of assets using fewer personnel, as well
of Internet of Things (IoT) and Digital Twin (DT), both fun- as to provide more information about the device that cannot
damental to Industry 4.0 [10]. IoT is based on the networking be collected by sensors.
of all objects [11]. When IoT is applied to industry, sensors Applied to factories, this technology involves the collec-
are themselves connected to the Internet and measurements tion and analysis of equipment data in real time, bringing
are sent to the cloud, from which they can be fetched and several benefits. The collected information is made available
displayed to maintenance personnel in a convenient way for to a user in a friendly way anywhere in the world through
real-time remote monitoring. This application is called the dashboard visualization (dashboards) implemented in web
Industrial Internet of Things (IIoT) [12]. pages or mobile applications (for tablets/smartphones). Bet-
The IIoT is connecting the physical world of sensors, ter tracking of industry assets allows for more assertive
devices and machines with the Internet, and by applying deep decision making, assistance in predictive maintenance of
analytics through software, is turning massive data into pow- equipment and production optimization [23], [24].
erful new insights and intelligence [13]. This advancement Given the potential gains of this tool, many works have
emphasizes extremely low latency, high reliability, security been published on induction motor monitoring [25]–[27].
and privacy, and can handle large amounts of data. In addi- The workflow of IoT-based monitoring is to employ a mi-
tion, the core of IIoT is to widely connect devices to perform crocontroller to read the analog measurements collected by
massive data collection and then use the algorithm models to sensors and, via a Wi-Fi module, to send the digitized data
perform in-depth data analysis to achieve broader value [14]. to an IoT-cloud provider over the Internet [25], [26]. In
Another concept commonly found in Industry 4.0 is DT, addition, the authors of [27] have also developed algorithms
which is the construction of a realistic computational model that estimate the operating state of the machine by anal-
(virtual replica) of the monitored device by means of analyt- ysis of simple characteristics of the power supply current
ical methods and tools [15]. High-fidelity virtual models are waveforms. However, these works do not use finite element
usually achieved with Multiphysics numerical simulations, analysis methods like the one proposed in this paper, which
such as the one performed in [16], in which a structural would result in more realistic models.
coupling technique was used to model a power transformer Other recent works using DT and IoT for fault prediction
under stressful operating conditions. With a digital twin it are [28] and [29]. At [28] introduces a system capable of
is possible, for example, to estimate the remaining device identifying combined faults of a rotating machine and pre-
lifetime and to evaluate its behavior under certain operating dicting faults, in a non-invasive machine manner. This iden-
conditions [17]. tification is done using different machine learning techniques
A Digital Twin is defined as a multi-physical, multi-scale, – namely support vector machines, k-nearest neighbors and
probabilistic, ultra-fidelity simulation that reflects, in time random forests – where they are compatible for classification
form, the state of the corresponding twin based on historical purposes. In the paper of [29], an IoT platform for real-time
data, real-time sensor data, and physical model [18]. In monitoring and remote visualization of power substations
this way, making it different from traditional simulations is proposed. In the work [30], neural networks are used
because the data used for simulation of the physical system by MATLAB/Simulink software that monitors performance
is collected and recorded from the physical system space and performs remote prognostics of electric motor health
via IoT. This definition meets the main characteristics of the in real time through the cloud, which is made the Digital
Digital Twin model to be demonstrated in this paper. The Twin through simulations using the finite element method.
main technologies of the DT concept can be summarized Furthermore, a paper recently published by the authors in [1]
into three categories, namely data related technologies, high proposes a monitoring based on DT system that numerically
fidelity modeling technologies and model-based simulation models the monitored motor using only input current mea-
technologies [19], [20]. surements.
According to [21], data-related technologies are responsi- In this scenario, the main contribution of this work is
ble for the process of data collection and transmission. They the use of the Finite Element Method (FEM) for the com-
employ a lot of sensors, meters, readers, cameras, scanners, putational development of a induction motor Digital Twin,
etc. However, the data that Digital Twins need is usually of considering a strong numerical coupling thermo-magnetic
large volume, high speed and great variety, which is difficult simulations [31]. Additionally, an IIoT system is used, which
and expensive to transmit to the Digital Twin in the server provides motor’s parameters (current and temperature) as
cloud. Thus, pre-processing methods for the collected data input data for the computer simulation. Moreover, improve-
are needed to reduce the network load and eliminate possible ments are also implemented in this work in order to achieve
data leakage. One of the ideal methods for data preprocessing more accuracy results, such as: additional monitored variable
is edge computing [22]. (temperature), offering a better accuracy of the virtual mo-
Given this, DT can be leveraged to a large extent by IoT tor model developed in FEMM and, consequently, a better
if the real-time data produced is used as input to build the analysis of the real motor conditions considered; validation
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regular time intervals and sends the digitized data through

a Wi-Fi access point to a cloud platform. The sent data are
stored in a database in the cloud, and are accessible in real-
time through a web page for visualization and further analysis
by the end-user. This data is used as input for the computer
simulations.

A. INDUCTION MOTOR
In this project, a three-phase 1.1 kW induction motor (param-
eters in Table I), connected in delta, is monitored. Its shaft
is connected to a Foucault brake (also called eddy current
brake), which acts as the mechanical load. The Foucault
brakes consist of an aluminum plate and current coils. The
FIGURE 1. The framework of the monitoring system implemented. coils’ DC current is varied through a potentiometer, hence
producing varying Foucault currents in the aluminum plate.
These eddy currents produce a magnetic field opposite to the
of the motor’s parameters mentioned above, aiming to obtain rotation of the motor axis [33], acting as a brake for the motor.
more reliable measurement values for the proposed system. In section IV, the motor will be subjected to different loads
In addition, new results were obtained such as the validation by varying the current on the Foucault coils.
of the motor current and temperature sensors, resistive losses
analysis in the stator and rotor, simulated temperature analy- TABLE 1. Parameters of the induction motor.
sis in the rotor and stator of the machine, and analysis of the
Description Value
conductivity of the motor windings. Efficiency class IE2 Class
The methodology of this paper is described as follows: Nominal power 1.1kW/1.5 cv
Thermal and current sensors are used to measure the temper- Number of phases 3
Voltage 220 V
ature and input current of a motor, respectively. Connected to Nominal current 4.42 A
the sensors is a microcontroller that samples and digitizes the Nominal Speed 1715 rpm
measurements. Next, a Wi-Fi sends the digital data to a cloud Power factor 0.80
Frequency 60 Hz
platform, where it is stored in databases. The measurements
stored in the cloud are accessible on the Internet via a web
page. Furthermore, the measured data stored in the cloud are
used as inputs to a numerical Finite Element Model simulated B. CURRENT ACQUISITION
in FEMM (Magnetic Finite Element Method) software [32] The motor supply current is monitored in one phase in the
to achieve a virtual replica of the motor according to the Dig- IoT device, consisting of the following components: clamp
ital Twin concept. The purposes of the numerical simulations current sensor SCT-013, signal conditioning circuitry and
are to realistically reproduce the operation of the monitored ESP32 microcontroller. The SCT-013 is a non-invasive sen-
motor and to obtain extra information that is not collected by sor that measures AC currents up to 100 A. It is based on
sensors, allowing one to have a deeper understanding of the the electromagnetic induction effect [33], where the magnetic
monitored device condition in a non-invasive way. field of the phase current induces a proportional current
in the sensor clamp. The split-core current transformer is
II. THE MOTOR MONITORING AND ANALYSIS SYSTEM composed of ferrite in the core and a dielectric strength of
In the context of this article, a DT application is designed to 1000 V between the shell and the output, in addition to the
perform the monitoring of industrial electrical equipment and nominal input current range between 10% up to 120% and
transmission of the measured data via the internet to users the supportable operating temperature of -25°C up to 70°C
in control of the industrial operation.The project described [34].
in this document is hereafter called Motor Monitoring and The sensor signal passes through a passive circuit (Fig.
Analysis System (from Portuguese, Sistema de Monitoriza- 2a) to be conditioned to a form suitable for being read by
ção e Análise de Motores - SMAM). ESP32 accurately, spurious oscillations are filtered out and
Fig. 1 shows the architecture of the SMAM system which amplification is performed to levels within the controller’s
comprises of four stages, namely the electrical machine being range. The conditioned signal is displayed on the ESP32’s
monitored, current and temperature acquisition cloud storage analog pins, digitized, and sent to the cloud via Wi-Fi. The
and post-processing of data through Finite Element Analysis ESP32 samples the current signal every second.
(FEA) and real-time graphs. In brief terms, there are sensors A Hioki power quality analyzer was also installed to mea-
connected to the motor continuously measuring the tempera- sure the supply current on the same phase monitored by the
ture on its frame and feed current. ESP32. This is a class A commercial equipment according to
An IoT microcontroller samples the sensor readings at IEC 61000-4-30 [35]. The current from the analyzer is used
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FIGURE 2. Diagrams of the (a) current and (b) temperature signal

conditioning circuits. Nodes pointed by labeled balloons indicate the points at
which the voltage signal is sampled by ESP32’s analog pins.
FIGURE 4. Preliminary calibration of SMAM’s current sensor. Feed current
measured by Hioki and by SMAM (before and after calibration).

FIGURE 3. Setup of the motor’s feed current and temperature measurement

by SMAM and reference equipment (Hioki, multimeter and thermal camera).

as reference data, that is compared with the measurements FIGURE 5. Fitting of calibration function.

from the proposed acquisition system for adjust and valida-

tion purposes. The Hioki analyzer is configured to sample
the current signal every second. Fig. 3 shows the overall fitted to the points using the method of least squares.This is
configuration of the measurements with the induction motor a calibration function whose input is the raw current reading
and the two current measurement systems (SCT-013 current from the TCS and the output is what the reference equipment
sensor and Hioki analyzer). would read if it were measuring the same current at the exact
Before the SMAM is deployed, the SCT-013 sensor must instant.
be calibrated in a preliminary round of measurements, using Once installed, the calibration function equation is imple-
readings from other equipment as a reference. In this article, mented in the ESP-32 software in order to correct the SMAM
such equipment is the Hioki analyzer. The Hioki and the current measurements in the implementation phase. The blue
SMAM are set to measure the motor supply current on the curve in Fig. 4 shows the SMAM measurements corrected
same phase. By varying the current in the eddy coils, the with the fitted function from Fig. 5, and the close agreement
motor is subjected to four increasing loads, one at a time and with the Hioki data is evidence of a successful calibration
for five minutes each. Current data is recorded throughout the procedure.
experiment, including the load transitions. Fig. 4 illustrates
the current signals measured by the two sensors during the C. TEMPERATURE ACQUISITION
calibration phase. In addition to the supply current, the SMAM also monitors
The current samples recorded at the same time by Hioki the temperature on the motor case side. The sensor used is
and SMAM are plotted against each other; the SMAM mea- an NTC (Negative Temperature Coefficient) thermistor. The
surements are associated with the horizontal axis. The result, MF52 series NTC thermistor is coated with an etoxylin resin
shown in Fig. 5, is an illustration of the relationship between and interconnected by a copper wire, where the rated power
the readings from two sensors that capture the same event is close to 50 mW and a temperature range from −55 ºC to
(current in the same phase) over time. A linear function is 125 ºC [36].
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FIGURE 7. Example of thermal image captured by FLIR camera.

Security), they are responsible, in the whole process of send-

ing, for the security of data against espionage and tampering
[37]. Thus, this type of encryption was used for connection
between the server and the developed system, because there
FIGURE 6. Temperature sensors and FLIR thermographic camera setup. is a concern with data security to avoid unwanted intrusions
into the confidential information of the industry, thus avoid-
ing problems in the production system.
A known resistor is connected in series with the NTC to For the exchange of messages with the server was chosen
form a voltage divider, as shown in Fig. 2b. The voltage the JSON model, because its format is intended to be a
across the resistor is read by the ESP32’s analog pins. The language of easy computational and human reading [38]. The
microcontroller code calculates the resistance of the NTC web server defined was the Heroku Postgres cloud platform, a
using the ratio of the voltage divider circuit and calculates free, online database service that internally uses PostgreSQL
the temperature from the resistance using the Steinhart-Hart database technology [39]. After sampling the measurements
equation. collected by the temperature and current sensors, the ESP32
For validation, the temperature is also measured by a microcontroller sends the digitized data to Heroku Postgres
thermocouple connected to a multimeter (Minipa model by calling the HTTP POST method. The data received by
ET2042E) and a thermal camera (FLIR T620). Fig. 6 shows Heroku is accessible through a specific web page, where the
the temperature-related part of the measurement setup. The end user can monitor the measurements in real time. The
thermocouple and NTC sensors are attached to the side of information is secure because only selected users who have
the motor housing; care was taken to ensure that the sensors received the web page link can access the data.
always touch the motor surface for accurate readings. The In addition to being able to view the stored measurements,
thermal camera is positioned at a distance of 1 meter from the end user can also schedule data retrieval for further anal-
the engine, and its image is focused on the insulating tape ysis by issuing GET requests (an HTTP method) to Heroku.
holding the other sensors. The camera was set up with After sampling the measurements collected by the temper-
emissivity = 0.94, the same value for the insulating tape. ature and current sensors, the ESP32 microcontroller sends
The temperature readings are recorded in different ways the data via Wi-Fi following the IEEE 802.11 communication
for the three sensors. The SMAM continuously sends sam- protocol.
ples to the cloud. The thermocouple measurement is recorded According to the manufacturer’s specifications [40], the
manually and from the thermal camera a thermographic module supports a data rate of up to 150 Mbps and 20 dBm of
image is captured, of which an example is shown in Fig. output power at the internal antenna, has internal 32-bit (dual
7. Preliminary measurements with all three devices revealed core) processors operating at 240 MHz and analog-to-digital
that no calibration of the NTC sensor was necessary. converters. In addition, it features a 1 kHz sampling rate and
floating point operations of the MFLOPS (million floating
D. COMMUNICATION WITH THE WEB SERVER AND point operations per second) type [41]. Thus, being sufficient
DATA STORAGE IN THE CLOUD for the desired communication in the SMAM project, elimi-
In this work, communications with the web server are per- nating the need to attach an external antenna to transmit the
formed using the HTTPS (Hypertext Transfer Protocol Se- information. This feature ensures a wide physical range for
cure) protocol since HTTPS has encrypted credentials, such data transmission.
as: SSL (Secure Socket Layer) and TLS (Transport Layer The measurements made by the ESP32 are sent to Heroku
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Postgres. The quality of the signal sent can be indicated tion and imposed (by an external source) current densities,
by the bit error rate (BER) which is based on the signal respectively. The conduction current density is related to the
strength [42]. In the transmission of information, between the electric field according to Ohm’s law
microcontroller and the Heroku server, this rate is low and is
proven by the successful calibration of the SMAM sensors J c = σE. (3)
that is described in topic II-B.
The magnetic constitutive relation is also of interest:
III. FINITE ELEMENT FORMULATION FOR
THERMO-MAGNETIC COUPLED PROBLEMS
The Finite Element Method (FEM) is a numerical technique B = µ(B)H, (4)
used to obtain approximate solutions to boundary value prob-
lems in Engineering. The domain of analysis is discretized where µ(B) is the medium’s magnetic permeability (func-
into a finite number of small parts (called elements), and in tion of B for nonlinear materials). Due to its zero divergence
each of those elements an algeberaic approximation of the (∇ · B = 0), B can be associated to a magnetic vector
governing equation is set up. The set of equations formed potential A as follows:
in all elements form a global system of equations, which is
calculated to solve for the unknown field(s) throughout the B = ∇ × A. (5)
domain of analysis [43].
Before the global system of equations is calculated, bound- Substituting (5) into Faraday’s law yields:
ary conditions need to be imposed on the solution domain.
The two most important boundary conditions in FEM are the ∂A
Dirichlet and periodic. ∇ × E = −∇ × , (6)
∂t
A high-fidelity, FEM-based model of the induction motor
was built in this work using the FEMM (Finite Element which, in the case of 2-D problems, can be integrated to result
Method Magnetics) software, widely used in literature. The in
inputs to FEMM are only the motor’s geometry and a few
easy-to-measure parameters such as phase current and tem- ∂A
E=− − ∇V. (7)
perature on the motor frame, excluding the massive amounts ∂t
of data needed by deep learning based techniques proposed In (7), the ∇V term is an additional voltage gradient that,
in other works. In the preprocessing phase of the simulations, in 2-D problems, is constant over a conducting body. This
FEMM solves four types of physics problems: magnetic, gradient is used by FEMM in harmonic problems to enforce
electrostatic, heat flow and current flow. This artifice occurs constraints on the current carried by conductive regions. By
for solving Maxwell’s equations. substituting a convenient combination of equations (3), (4),
In this paper, the realistic operation of the induction motor
(5), (7) into (2), we obtain.
was simulated numerically, considering the strong coupling
(two-way interdependence) between thermal and magnetic  
effects based on the work [44]. To process this simulation, 1 ∂A
∇× ∇×A = −σ − σ∇V + J src . (8)
FEMM needed to solve equations regarding low frequency µ(B) ∂t
electromagnetic models and Thermal Formulation described
in the subsection below. Equation (8) is solved in phasor form by software FEMM
for time-harmonic magnetic problems.
A. LOW-FREQUENCY ELECTROMAGNETIC MODEL By dimensional analysis, each additive term at the right-
A detailed mathematical model is given in [43] on the hand side of (8) is a form of current density. Defining the first
FEM formulation and thus our focus will be on Maxwell’s term as
equations in the form solved by software FEMM [45]. Two
important Maxwell’s equations are the Faraday-Lenz and ∂A
J e = −σ , (9)
Ampère laws, which, in the low-frequency approximation, ∂t
are respectively written as [33]
One can interpret that, apart from the gradient term, there
∂B are two types of electric currents involved in induction mo-
∇×E =− (1)
∂t tors: source current in the stator armature J src and the current
and induced J e by the rotating magnetic field. During simula-
tions, the resistive losses (q) due to current flow through the
∇ × H = J = J c + J src , (2) copper strands are calculated [46].
where E is the electric field vector, H the magnetic field, 1 2
B the magnetic flux density, J c and J src are the conduc- q= J . (10)
σ
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FIGURE 9. Conductivity calculation.

FIGURE 8. Algorithm for numerical simulations with strong thermo-magnetic

coupling.

B. THERMAL FORMULATION
The thermal formulation solves the problem of transient heat
FIGURE 10. Modification of materials.
conduction, governed by the equation [45]
dT
ρ cp − ∇ · (k∇T ) = q, (11) iteration, the magnetic simulation is run, in which equation
dt
where ρ is the mass density, cp the specific heat capacity, k (8) is solved numerically to calculate the potential of the
the thermal conductivity and T temperature. Equation (11) is magnetic vector A in all finite elements that form the analysis
solved by software FEMM by discretizing time with Euler’s region. In addition, the resistive losses in the copper strands
implicit discretization scheme. After calculating the tempera- are calculated using equation (10).
ture values at all the finite elements of the analysis domain by Next, the thermal simulation is started where equation (11)
numerically solving (11), software FEMM updates the values is solved numerically on all finite elements, using the resis-
of electric conductivity using the equation [46] tive losses calculated in the previous magnetic simulation as
heat sources. The electrical conductivities are updated at the
1 new temperatures according to (12). To do this, it is necessary
σ(T ) = , (12)
ρ0 (1 + β0 ) T to state equations (11) and (12) in the code, in addition to the
where ρ0 is the electrical resistivity at 0◦ C and β0 the rate of geometric coordinates of each part of the stator and rotor. In
variation of resistivity with temperature. Fig. 9 the realization of this process in the developed program
is illustrated.
C. ALGORITHM FOR STRONG THERMO-MAGNETIC The calculated values are stored and reintroduced into
COUPLING the magnetic simulation of the next step by means of the
The multiphysics coupling was obtained from the pyFEMM repeat present in the code. The condition set in this repetition
package that allows simulations to be performed in FEMM updates the conductivity values with the mimodifymaterial
from the Python programming language. The code consists function as illustrated in Fig. 10. This process is repeated
of calculations that are performed iteratively over time, where until the simulated time period is complete.
each iteration is composed of a magnetic simulation and
followed by a thermal simulation. Fig. 8 shows the block D. POST-PROCESSING OF DATA USING FINITE
diagram of the coupling algorithm used. ELEMENT ANALYSIS (FEA)
As illustrated in Fig. 8 the output of each simulation is As the main contribution of this work, the monitored equip-
used as the input of the other to obtain a strong coupling, this ment is also numerically simulated using the measured tem-
type of interaction is able to faithfully represent the simulated perature and the the current as inputs. With the numerical
physical phenomenon [47] [48]. At the beginning of each model, it is possible to obtain information that is not provided
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by the sensors, for example resistive losses in the stator

and rotor, in order to better understand the state of the
monitored device. The idea is to accurately reproduce the
current operating conditions of the motor with numerical
models, which allows a complete analysis of its behavior and
condition without the need to shut down the motor or install
invasive sensors.
The open source software FEMM (Finite Element Method
Magnetics) is used in simulations and the following data are
required as inputs: the geometric model, boundary condi-
tions, electromagnetic material parameters and supply cur-
rent. The Galerkin boundary condition (A=0) is used. The
electromagnetic parameters of the modeled motor parts are
listed in Table 2.
FIGURE 11. Motor’s phase current at different load conditions, as measured
TABLE 2. Electric parameters of materials used in FEMM simulation. by Hioki and SMAM devices.
Material Component(s) Relative Electrical Thermal
Permeability Conductivity Conductivity
(MS/m) (W/m.K)
Aluminum Rotor 1 34.45 84 Hioki, is due to the direct on-line starting of the motor.
armature
M-45 Steel Rotor and 4689 2.90 52
After that, the motor enters steady-state regime with small
Stator core jumps in current, considering five minutes apart from each
Air Air gap 1 0 0.03 other, which correspond to the load levels being applied
Copper Stator 1 58 70
armature
successively.
There is good agreement both in transient and steady-state
regimes, with the error of SMAM’s readings relative to Hioki
To perform the thermal-magnetic coupling using FEM, the equal to 13.6% for the starting peak and 4.4% on average
following data are required as input: total losses obtained during steady state. The relatively low errors for the current
from the magnetic simulation in the thermal simulation, the measurements of SMAM demonstrate that it is possible to
material according to its thermal properties obtained from use low-cost sensors to leverage the benefits of IoT and DT
[31], convection boundary condition, also specifying the on a large scale, with little compromise of accuracy.
thermal conductivity (W/m.K) and the ambient temperature. During the experiment, besides current, temperature on
The simulation feed-in current and ambient temperature are the side of the motor casing was also monitored by SMAM,
based on the values measured by the corresponding sensors, thermocouple and thermal camera. After the motor has been
obtained from the database. Relatively the mesh used con- running for five minutes under each load level, the tempera-
tained 92294 triangular elements and 46426 nodes. ture readings of the thermocouple and thermal camera were
manually captured and compared to with the NTC values
IV. RESULTS at that same time instant. The strongly coupled thermo-
A. MONITORING PHASE CURRENT AND magnetic model of the induction motor was also simulated in
TEMPERATURE ON THE MOTOR FRAME AT DIFFERENT FEMM software to obtain simulated values of temperature.
LOADS
Fig. 12 shows the simulated and measured temperatures on
The acquisition setup described in section II was employed the side of the motor casing. All values start close to 27◦ C,
to monitor the feed current and temperature of the induction which was the room’s ambient temperature before measure-
motor. Notice that the measurements reported here took place ments began. It is observed for all sensors the pattern of rising
after SMAM’s current sensor was calibrated according to the temperature as load levels increase, which is expected as the
procedure of section II-B e II-C. higher motor current dissipates more heat. For all load levels
By varying the current of Foucault coils with the po- the temperature measured by the sensors are very close to
tentiometer, the motor was subjected to four load levels each other. The simulated values tended to be higher than the
successively, for five minutes each. In this study we will refer measured ones, in part because the effect of heat exchange
to those loads as I, II, III and IV. At load I there is no current with air was not taken into account in simulations.
into the Foucault coils, there is only the inertia of the Foucault
The percentage errors of FEA temperatures relative to
brakes. At loads II, III and IV the current into the Foucault
SMAM’s readings are shown in bars. All relative errors are
coils is 3 A, 3.5 A and 4 A, respectively.
less than 10%, indicating that simulations model thermal
The current data collected by Hioki and SMAM’s cal-
aspects of the motor with high fidelity.
ibrated sensor are illustrated in Fig. 11. The initial peak,
as 20.33A measured by SMAM and 17.90A measured by
8 VOLUME 4, 2016

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 This article has been accepted for publication in IEEE Access. This is the author's version which has not been fully edited and
content may change prior to final publication. Citation information: DOI 10.1109/ACCESS.2022.3232063

Author et al.: Preparation of Papers for IEEE TRANSACTIONS and JOURNALS

FIGURE 12. Simulated and measured values of temperature on the side of

the motor frame. FIGURE 14. Simulated electromagnetic torque as a function of rotor angle for
the induction motor considered in this work.).

FIGURE 13. Simulated magnetic flux density in the induction motor.

B. FINITE ELEMENT ANALYSIS OF TORQUE AND

RESISTIVE LOSSES OF THE INDUCTION MOTOR
FIGURE 15. Average resistive losses per slot at stator and rotor across load
The objective of using the finite element analysis is to make levels.
a thorough diagnosis of the electromagnetic behavior of the
motor using a method that has no interference with the
operation of the motor being analyzed. Using this method, profile while varying the rotor angle by steps of 5 degrees. It
it is able to extract the resistive losses in the stator armature can be observed that there is a maximum torque of 4.825N.m
as well as the torque via the Weighted Stress Tensor method at 250 degrees and minimum value of 4.47N.m at 95 degrees.
[49]. The curve presents an expected pattern of variation. Since
This simulation is done considering the motor is operating the modelled motor has a cylindrical rotor (Fig. 13), the air-
under different levels of load conditions. As input current gap permeance is somewhat constant with rotation, causing
to the simulation, it is considered the steady state currents the electromagnetic torque to oscillate by a relatively small
from 3A to 4A with an interval of 0.5A, as measured by amount around an average value [49].
SMAM. Fig. 13 shows the distribution of magnetic flux Next, the electrical losses in the motor windings were
density (MFD) in the induction motor at load II (Fig. 12). analyzed as illustrated in Fig. 15. Considering that resistivity
As expected by theory, MFD is more intense in the stator’s is directly influenced by temperature as shown in equation
and rotor’s ferromagnetic materials. (12), it is expected that the resistive losses increase at each
As mentioned before, torque results are obtained via the load level. Furthermore, for each load level, the steady state
Weighted Stress Tensor method in FEMM how explained in current was simulated for a duration of 38 ms in order to
the reference [49]. Fig. 14 shows the induction motor torque verify that the losses are constant during that period.
VOLUME 4, 2016 9

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content may change prior to final publication. Citation information: DOI 10.1109/ACCESS.2022.3232063

Author et al.: Preparation of Papers for IEEE TRANSACTIONS and JOURNALS

FIGURE 16. Temperature distribution (in Kelvin) in the motor.

FIGURE 18. Algorithm for numerical simulations with strong thermo-magnetic

coupling.

by the sensors and infrared camera. This has greater impor-

tance as winding can reach temperatures harmful to insula-
tion and decrease its service life [50].
Moreover, in view of the temperature obtained by the
model, it is possible to calculate the conductivity of the
windings of the stator and rotor from (12). The results are
presented in the graphs in Fig. 18.
In the graphs, it is observed that the conductivity values
have variations for each current load level. In this case it is
expected that there should be a reduction of the conductivity
with the increase in temperature. This is further affirmed by
[50], which proposed a design optimization of an axial-field
eddy-current magnetic coupling based on magneto-thermal
FIGURE 17. Algorithm for numerical simulations with strong thermo-magnetic analytical model. As observed in Fig. 19, there is excellent
coupling.
agreement between the stator simulated conductivity and
proposed by [50], with relative errors less than 4%, thus
Having obtained the losses in the windings, they were validating the results.
entered as input for thermal simulation, according to the
strong coupling shown in Fig. 8. In order to validate the V. FINAL REMARKS
results, a FLIR thermographic camera (an infrared camera), This paper deals with an application of the Industrial Internet
temperature sensors on the thermal acquisition model and a of Things (IIoT) and computer simulations as tools for Dig-
thermocouple connected to a multimeter were used. The FEA ital Twin, with the aim of enabling a more detailed analysis
performed by the software resulted in the temperature distri- of the induction motor. For this purpose, an IoT module is
bution illustrated in Fig. 16 for load level II. It is noticed that developed with sensors for measuring the motor’s current and
the copper strands are the points with highest temperature in temperature. The measurements are entered into the FEMM
both coils, as expected. An average temperature of 44◦ C in software where strong coupled thermo-magnetic finite ele-
the motor is observed, which is in line with insulation class ment analysis (FEA) is performed in order to enable the
(F) as specified by the manufacturer. operator to understand the thermo-magnetic behavior of the
In addition, it is possible to observe in Fig. 17 the average motor in a non-invasive way, providing useful information
temperature graphs in the stator and rotor slots. for important tasks such as predicting potential failures.
From this, it is noted that during the steady state time The proposed system was used on an induction motor
interval for each load level, the average temperature in the in a controlled environment. Commercial sensors were also
windings remains approximately constant. Furthermore, due installed to measure the same variables for comparison pur-
to not taking into account the cooling effect from the motor’s poses. The motor’s phase current and temperature in steady
ventilator, the simulated temperature is above that measured state measured by our system agreed very well with the
10 VOLUME 4, 2016

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content may change prior to final publication. Citation information: DOI 10.1109/ACCESS.2022.3232063

Author et al.: Preparation of Papers for IEEE TRANSACTIONS and JOURNALS

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of Harmonics". Energies, 15, 2022. in the area of seismic signal processing for oil
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JHENNIFER F. DOS SANTOS is a student of

Electrical Engineering at the Federal University
ALLAN R. A. MANITO He has a bachelor’s
of Pará (UFPA), she graduated in Microcomputer
degree in electrical engineering from the Federal
Maintenance at Instituição Salesiana do Trabalho,
University of Pará (2006), a master’s degree in
with experience in computer maintenance. Cur-
electrical engineering in the area of power sys-
rently she is in a scholarship in the Laboratory
tems also from UFPA (2009), and a doctorate in
of Design and Analysis of Electromechanical De-
electrical engineering in the area of power systems
vices (LCADE) at the Center of Excellence in
from UFPA (2019). He works as a professor at the
Energy Efficiency in the Amazon (CEAMAZON),
School of Electrical and Biomedical Engineering
where she develops and research on Internet of
at UFPA. His main research interests are in the
Things in Industry (IIoT), electric motors, automation of industrial pro-
following areas: High Voltage, Power Quality and
cesses, predictive maintenance and energy efficiency.
Energy Efficiency.

12 VOLUME 4, 2016

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 This article has been accepted for publication in IEEE Access. This is the author's version which has not been fully edited and
content may change prior to final publication. Citation information: DOI 10.1109/ACCESS.2022.3232063

Author et al.: Preparation of Papers for IEEE TRANSACTIONS and JOURNALS

WELLINGTON S. FONSECA He holds an un-

dergraduate degree in Physics from the Federal
University of Pará (2007) and a Master’s and
PhD in Electrical Engineering from the Federal
University of Pará (2010 and 2016, respectively).
Post-Doctorate at COPPE-UFRJ (2019). Professor
at UFPA since 2011, he is currently a Professor
at the Institute of Technology of the Federal Uni-
versity of Pará - ITEC/FEEB. He is a researcher
at CEAMAZON - Center of Excellence in Energy
Efficiency in the Amazon. Professor of the Graduate Program in Mechanical
Engineering - PPGEM and of the Graduate Program in Electrical Engineer-
ing - PPGEE. Reviewer of Journals and Scientific Events, such as Interna-
tional Journal of Applied Electromagnetics and Mechanics, IEEE Access,
IEEE/IAS International Conference on Industry Applications - INDUSCON,
Journal of Studies and Research on Technological Education, among others.
Has experience in the area of Energy, Principles of Industry 4.0, Low
Frequency Electromagnetism, Interactions between Electromagnetic and
Mechanical Phenomena, Electrical Materials, Finite Element Method, Finite
Volume Method.

MARCELO O. SILVA received the B.Sc. and

master’s degrees in mechanical engineering from
the Federal University of Pará, Belém, Brazil,
in 2000 and 2002, respectively, and the Ph.D.
degree in mechanical sciences from the Federal
University of Rio de Janeiro, Brazil, in 2007. He
has experience in mechanical engineering, with
emphasis on fluid mechanics, working mainly on
the following topics: natural convection, bipha-
sic flow, abrupt expansion, electroresistive sensor
technique, limit layer, asymptotic analysis, pneumatic transport, and experi-
mental techniques.

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