Lab View based Automated Motor Test Bench for
Induction Motors
[Link] Tauqeer Dr. [Link]
`Hamza Shoukat
Electrical Engineering Dept. Electrical Engineering Dept.
Electrical Engineering Dept.
Information Technology University Information Technology University
Information Technology University
Lahore , Pakistan Lahore , Pakistan
Lahore,Pakistan
[Link]@[Link] [Link]@[Link]
[Link]@[Link]
Muhammad Sohaib Syed Zain ul Abidin
Dr. Usman Younis
Electrical Engineering Dept.
Electrical Engineering Dept. Electrical Engineering Dept.
Information technology university
Information technology university Information technology university
Lahore,Pakistan
Lahore,Pakistan Lahore,Pakistan
[Link]@[Link]
[Link]@[Link] [Link]@[Link]
Abstract—Induction motors comprises more than 90% of Efficiency = Pout/Pin where
the industrial load. With the passage of time Induction motors Pout=Tw & Pin=VIcosФ (for single phase)
are prone to losses. To save energy consumption, predictive
maintenance of motors must be carried out at regular
Pin=(3)0.5VIcosФ (for three phase)
intervals. Industrial monitoring and automation lab has Pout ……………….. output mechanical power
developed state of the art motor test bench facility which is Pin………………….input motor power
completely automated using LabVIEW software which is a T………………….. Torque
widely used industrial software. The manual methods of motor w………………….. Angular speed
testing are not only hectic but also not reliable. A systematic
approach has been adopted to measure and analyze various B. General layout of test bench
parameters of the induction motor, which will help us to Major components of motor test bench includes magnetic
identify key performance factors. . In addition to cost, energy powder break, torque sensor, torque speed data
savings will help to reduce the load on the national grid. This acquisition instrument, power analyzer,3 phase power
paper aims at the development of automated test bench for supply, programmable dc power supply, cooling system,
induction motors and identify trends found in locally temperature monitoring system and computer & printer.
manufacturer’s designed motor. Moreover to identify faults The block diagram depicts the working of motor test
associated with industrial motors in order to prolong life and bench below
make them work efficient.
Keywords- LabVIEW, predictive maintenance, motor test
bench
I. INTRODUCTION
A. Overview
A state-of-the-art motor test bench has been developed in
the industrial monitoring and automation lab (IMAL) at
Information Technology University, which is capable of
testing the single and three-phase induction motor with a
power rating of 0-15hp. According to IEC60034-2-1
standard [1], our system is capable to measure different
parameters of the induction motor such as voltage, current,
real power, reactive power, apparent power, power factor, Figure 1 General Layout Motor Test Bench
insulation resistance, inductance, capacitance, impedance,
temperature, torque and speed, also using these parameters, C. LabVIEW platform
various experiments such as No-Load test, Locked Rotor Laboratory Virtual Instrumentation Engineering Workbench
test, Temperature Rise test, DC Winding test, Efficiency and has user friendly interface when it comes to controlling,
losses are measured to evaluate the performance of induction testing applications using graphical user interface [3]. The
motor. logic is built in the form of block diagram for graphical
We are using direct method which is relatively easy programming. The change in motor torque and speed can be
as compared to indirect method to find the efficiency of obtained using varying loads on motor. The characteristics
induction motor. In direct method [2], we use motor input graphs of motor torque and speed are displayed via
and output mechanical power to calculate the efficiency LabVIEW graphical user interface.
using the formula.
XXX-X-XXXX-XXXX-X/XX/$XX.00 ©20XX IEEE
D. Torque Sensor Real Power(W) Real power(W) of induction motor
The FUTEK TRD305 torque sensor we are using can be
used for measuring steady rotating torque and dynamic Reactive Reactive power(VAR) of induction
torque as well. It can operate up to 3000 r.p.m @ 100N-m. Power(VAR) motor
This typical sensor fetches torque signals using strain Apparent Apparent power(VA) of induction motor
electrical measuring technology [8]. The rotation speed or Power(VA)
direction of motor does not affect measuring accuracy of Power Power factor of induction motor
torque. Moreover the torque sensor is compact, lightweight, factor(cos Ф)
and reliable and can easily be deployed with our test bench
facility. Temperature (T) Temperature measurement of motor and
powder brake
E. Powder break Torque(N-m) Torque measurement up to 100N-m
We are using Fz-100j magnetic powder break in our motor
test bench. Its allowable rotational speed is 1500 r.p.m. and Speed (RPM) Speed measurement of motor
supports up to 100 N-m torque.
Losses Measurement of losses both stator and
rotor
II. METHODOLOGY Total Harmonic Total Harmonic Distortion up to 50th
Distortion(THD)
Phase Analysis Phaser analysis of the induction motor
Motor characterization test bench consists of the following
components: Powder break, Powder brake Table with
adjustable motor fixture and chassis, power supplies, Insulation Insulation resistance of induction motor
controller, and customize motor testing software. resistance
These are the following objectives of developing the motor (Ohms)
characterization test bench. Inductance (H) Inductance of induction motor
● Develop test cases to determine the induction Capacitance (F) Capacitance of induction motor
motor parameters such as RPM vs Torque
Impedance Impedance of induction motor
● Validate the measurements using a third-party (Ohms)
motor characterization test bench for initial
calibration B. Motor Test Bench Tests
● Develop an integrated system to generate motor No Load Test is an indirect method used to determine
performance reports
efficiency and to determine the circuit parameters of an
● Develop a feedback mechanism such that the
equal circuit of three-phase motors. The rated voltages are
design improvements are validated using the
applied to the stator terminals with a rated frequency with a
repeated motor characterization
rotor not connected to any mechanical load. The voltage is
● Using measuring parameters, the following
experiments can be performed to evaluate the increases slowly and is applied to the machine at rated
performance of the induction motor such as voltage. Motor runs at synchronous speeds at this point.
no-load test, This test gives the information regarding no-load losses
locked rotor test, such as core loss, friction loss and windage loss [4]. Rotor
full load test, copper loss at no load is very less that its value is negligible.
DC winding resistance test
In the locked rotor test, it should be kept in mind that
the applied voltage on the stator terminals should be low
A. Measuring Parameters otherwise normal voltage could damage the winding of the
Table 1
stator. In block rotor test, the low voltage is applied so that
PARAMETER DESCRIPTION the rotor does not rotate and its speed becomes zero and full
load current passes through the stator winding. The slip is
Voltage(V) Line to Line(L-L) and Line to
Neutral(L-N) voltage unity related to zero speed of rotor hence the load resistance
Current(A) Single phase and three phase current of becomes zero. Now, slowly increase the voltage in the stator
induction motor
winding so that current reaches to its rated value. The values
of voltage, power and current are observed through power
analyzer. The test can be repeated at different stator voltages
for the accurate value.
The Full load test on induction motor is performed to
compute its complete performance i.e., torque, slip,
efficiency, power factor etc. During this test, the motor is
operated at rated voltage, frequency and normally loaded
mechanically by brake until motor reach at rated current
at this point measure the motor power factor, apparent
power, real power, and motor efficiency. Make sure input Figure 3 Current-Speed Curve
and output power connectors are well-coupled.
In DC winding resistance test if a DC voltage is
applied to the stator terminals, there will be no potential
difference across any inductance and no induced voltage on
the rotor. As a result, the per-phase circuit is reduced to the
stator winding resistance. Applying a DC voltage across two
motor terminals and measuring the current, the stator
resistance can be found. While detecting problems in vital
motors or generators is important, finding them before they
lead to catastrophic failure is critical. Predictive and
preventive maintenance which include regular testing can Figure 4 Load-Speed Curve
help detect winding issues early. [5]Winding resistance tests
provide information about the condition of the windings.
C. Characteristics Plots
Figure 5 Load-Current Curve
D. Data Acquisition
The controller we have interfaced with the test bench system
is NI cRIO-9063 for data acquisition through LabVIEW. It
Figure 2 Torque-Speed Curve is based on arm cortex-A9 architecture with clock speed of
[Link] test bench comprises of NI-DAQ chassis (NI
9939) designed for remote measurements. In addition to
this, DI/O (NI 9422) card module have been attached to
calculate r.p.m of motor beside with temperature sensor
module (NI 9210). The figure below shows the logic
diagram for acquiring motor parameters, torque and
temperature data. Using energy meter we find apparent
power, power factor and other parameters then we double to design efficient motors. This shall help businesses to
check with hioki meter to compare if results are correct. develop energy efficient induction motors and provide value
added services. Additionally, the cost and energy savings
will help to reduce the load on the national grid.
This test bench, which will help the recruited staff
in the development of a multitude skills. The development
of the test bench will help in understanding the basic
working of the induction motors and international standards
that are followed for producing the motor of export-quality.
We will also help the local industry to train their employee.
Figure 6 Data acquisition LabVIEW logic III. RESULTS & DISCUSSIONS
The induction motor’s synchronous speed is given as
Nsync =120xfrequency/no. of poles
Where,
Nsync is synchronous speed of magnetic fields
Rotor slip is calculated as
S= (nsync-nm)/ nsync
Where,
S is slip of machine
Nm is shaft speed of motor
Rotor frequency can be stated as
fr =P(nsync-nm) E/120
Where,
fr is frequency of motor Figure 7 Motor characterization Test Report
E. Impact on principle Discipline of Research Figure 7 shows the comparative results in which we have
performed various tests i.e. no-load test, rated load test,
According to Engineering Development Board (EDB) rated load current voltage balance test, DC winding
Import / Export statistics of Engineering Industry of resistance test. The parameters thus obtained from various
Pakistan (JUL-JUN 2016-17 & 2015-16) [6] Engineering tests indicate the motor is running under normal conditions.
The actual data acquisition by LabVIEW at various loading
share in total exports was 4.32% and 4.18% in the year conditions indicates the validity of results obtained when
2015-16 & 2016-17 respectively on the other hand compared with theoretical calculations. 1% tolerance is
engineering share in total imports was 37.11% and 38.88% acceptable in each test in our case .All the relevant data can
be saved in TDMS file format which can be accessed any
in the year 2015-16 & 2016-17 respectively and that is time.
continuing to grow with each passing day. Pakistan exported
motors of different ratings, including single-phase and
multiphase motors having a worth of PKR 3.3 Billion and
PKR 3.04 Billion in the years 2015-16 and 2016-17,
respectively. We can massively increase the exports of
motors from Pakistan after developing modern motor testing
facilities and certify the motors according to International
standard IEC 60034-2-1 [7] that will also increase the job
opportunities.
By the establishment of this test bench, we will
play a more active role in the optimization of induction
motors, which will help the industry to function more
effectively. Our feedback and recommendations based on
Figure 8 Motor Test Bench Assembly
the motors testing will help the motor producing industries
V. REFERENCES
IV. CONCLUSION
In this paper, it has been demonstrated that we have [1] "IEC 60034-1 International ElectroTechnical Comission,"
successfully automated motor test bench using LabVIEW May 2017. [Online]. Available: [Link]
data acquisition. When we compared the efficiency of our preview/info_iec60034-1%[Link]%[Link].
test bench with other such systems in the market, its results [2]"IEEE Standard Test Procedure for Single-Phase Induction
are more reliable and have low operating/testing cost Motors," in IEEE Std 114-2001 , vol., no., pp.1-37, 24 May 2002,
associated with it. The stored data can be used for analysis of doi: 10.1109/IEEESTD.2002.93615.
performance of induction motor. By comparing between
simulated and practical behavior of induction motors we can [3] N. Kehtarnavaz, "ScienceDirect," 2008. [Online]. Available:
differentiate the credibility of reports. Moreover industrial [Link]
motor losses can be prevented beforehand by timely testing science/virtual-instrument.
of induction motors. [4] "Electrical4U," 26 october 2020. [Online]. Available:
[Link]
ACKNOWLEDGMENT induction-motor/.
We are grateful to the Department of Electrical [5] "IEEE Guide: Procedures for Testing Single-phase and
Engineering Information Technology University together Polyphase Induction Motors," The Institute of Electrical and
with other collaborators involved in the research and Electronics Engineers, Inc 345 East 47th Street, New York, NY
development automated test bench system. Industrial 10017, USA , New York, 1986 April 7th.
monitoring and automation lab has been a key platform
where we implemented this project. The whole team is worth [6] "Engineering Development Board," Islamabad.
appreciable who contributed towards the development of [7] "Pakistan2025 One Nation-One Vision," Ministry of Planning,
automated motor test bench system. Islamabad.
[8] "FUTEK," FUTEK advanced sensor [Link], [Online].
Available:
[Link]
