Mechanical fault detection of electric motors by laser vibrometer and accelerometer measurements

This paper presents a comparative study between accelerometer and laser vibrometer measurements aimed at on-line quality control carried out on the universal motors used in washing machines, which exhibit defects localised mainly in the bearings, including faults in the cage, in the rolling element and in the outer and inner ring. A set of no defective and defective motors were analysed by means of the acceleration signal provided by the accelerometer, and the displacement and velocity signals given by a single-point laser vibrometer. Advantages and disadvantages of both absolute and relative sensors and of contact and non-contact instrumentation are discussed taking into account the applicability to real on-line quality control measurements and bringing to light the related measurement problems due to the specific environmental conditions of assembly lines and sensor installation constraints. The performance of different signal-processing algorithms is discussed: RMS computation at steady-state proves effective for pass or fail diagnosis, while the amplitude of selected frequencies in the averaged spectra allows also for classification of a variety of special faults in bearings. Joint time-frequency analysis output data can be successfully used for pass or fail diagnosis during transients, thus achieving a remarkable reduction in testing time, which is important for on-line diagnostics.