FAULT ANALYSIS AND PREDICTIVE MAINTENANCE SIMULATION AND ANALYSIS OF INDUCTION MOTOR PID CONTROL SYSTEMS

Abstract

In closed-loop induction motor drives, conventional PID regulators inherently mask early-stage machine degradation by continuously compensating for output tracking errors. This paper evaluates these limitations through a multi-signal simulation model implemented in MATLAB/Simulink, titled "Fault Analysis and Predictive Maintenance Simulation and Analysis of Induction Motor PID Control Systems." Utilizing dual parallel branches with identical PID gains (K_p = 5.23, K_i = 12.45, K_d = 0.08), a 5.5 kW motor is subjected to a cascading fault sequence: an electrical Inter-Turn Short Circuit (1.5–2.5 s), a structural Phase Loss (2.5–3.5 s), and a mechanical Overload (3.5–5.0 s).

The results demonstrate that while the PID loop maintains average velocity tracking at 150 rad/s, it fails to mitigate severe high-frequency torque ripples and stator overcurrent’s. Following phase loss and overload injection, the RMS stator current escalates to 10.5 A and 12.3 A, respectively, breaching the machine's 11 A rated safety threshold. To address this masking effect, a multi-parameter diagnostic vector fusing speed errors, torque pulsations, RMS currents, and Total Harmonic Distortion is mapped into a unified Predictive Maintenance Health Index. This indicator transforms complex operational distress into distinct, stepped transitions (surging from 0.95 to 7.85) that successfully breach Warning and Critical thresholds in real time, validating the framework as a reliable prognostic tool for industrial asset monitoring.