Effective algorithms for real-time wind turbine condition monitoring and fault-detection

Reliable condition monitoring (CM) can be an effective means to significantly reduce wind turbine (WT) downtime, operations and maintenance costs and plan preventative maintenance in advance. The WT generator voltage and current output, if sampled at a sufficiently high rate (kHz range), can provide a rich source of data for CM. However, the electrical output of the WT generator is frequently shown to be complex and noisy in nature due to the varying and turbulent nature of the wind. Thus, a fully satisfactory technique that is capable to provide accurate interpretation of the WT electrical output has not been achieved to date. The objective of the research described in this thesis is to develop reliable WT CM using advanced signal processing techniques so that fast analysis of non-stationary current measurements with high diagnostic accuracy is achieved. The diagnostic accuracy and reliability of the proposed techniques have been evaluated using data from a laboratory test rig where experiments are performed under two levels of rotor electrical asymmetry faults. The experimental test rig was run under fixed and variable speed driving conditions to investigate the kind of results expected under such conditions. An effective extended Kalman filter (EKF) based method is proposed to iteratively track the characteristic fault frequencies in WT CM signals as the WT speed varies. The EKF performance was compared with some of the leading WT CM techniques to establish its pros and cons. The reported experimental findings demonstrate clear and significant gains in both the computational efficiency and the diagnostic accuracy using the proposed technique. In addition, a novel frequency tracking technique is proposed in this thesis to analyse the non-stationary current signals by improving the capability of a continuous wavelet transform (CWT). Simulations and experiments have been performed to verify the proposed method for detecting early abnormalities in WT generators. The improved CWT is finally applied for developing a new real-time CM technique dedicated to detect early abnormalities in a commercial WT. The results presented highlight the advantages of the improved CWT over the conventional CWT to identify frequency components of interest and cope with the non-linear and non-stationary fault features in the current signal, and go on to indicate its potential and suitability for WT CM.</div

Degradation feature extraction method for piezoelectric ceramic of ultrasonic motor based on DCT-SV cross entropy

Crack on piezoelectric ceramic is the main reason leading to failure of ultrasonic motors. A novel degradation feature extraction method based on discrete cosine transform (DCT) -singular value (SV) cross entropy was proposed in this paper. In order to improve the correlation with the crack, the DCT coefficients with the property of energy aggregation, were used to extract fault information. To avoid the influence of human factors in traditional DCT de-noising method, a matrix composed of DCT coefficients was constructed, and the SV cross entropy of the matrix was taken as the degradation feature for ultrasonic motor. A numerical simulated noise was added to the measured signal to verify the anti-noise performance of the feature. Analysis of the experimental results demonstrates that the proposed DCT-SV cross entropy is feasible and effective in indicating the degradation of piezoelectric ceramic in ultrasonic motor

Studies in Electrical Machines & Wind Turbines associated with developing Reliable Power Generation

The publications listed in date order in this document are offered for the Degree of Doctor of Science in Durham University and have been selected from the author’s full publication list. The papers in this thesis constitute a continuum of original work in fundamental and applied electrical science, spanning 30 years, deployed on real industrial problems, making a significant contribution to conventional and renewable energy power generation. This is the basis of a claim of high distinction, constituting an original and substantial contribution to engineering science

MACHINERY ANOMALY DETECTION UNDER INDETERMINATE OPERATING CONDITIONS

Anomaly detection is a critical task in system health monitoring. Current practice of anomaly detection in machinery systems is still unsatisfactory. One issue is with the use of features. Some features are insensitive to the change of health, and some are redundant with each other. These insensitive and redundant features in the data mislead the detection. Another issue is from the influence of operating conditions, where a change in operating conditions can be mistakenly detected as an anomalous state of the system. Operating conditions are usually changing, and they may not be readily identified. They contribute to false positive detection either from non-predictive features driven by operating conditions, or from influencing predictive features. This dissertation contributes to the reduction of false detection by developing methods to select predictive features and use them to span a space for anomaly detection under indeterminate operating conditions. Available feature selection methods fail to provide consistent results when some features are correlated. A method was developed in this dissertation to explore the correlation structure of features and group correlated features into the same clusters. A representative feature from each cluster is selected to form a non-correlated set of features, where an optimized subset of predictive features is selected. After feature selection, the influence of operating conditions through non-predictive variables are removed. To remove the influence on predictive features, a clustering-based anomaly detection method is developed. Observations are collected when the system is healthy, and these observations are grouped into clusters corresponding to the states of operating conditions with automatic estimation of clustering parameters. Anomalies are detected if the test data are not members of the clusters. Correct partitioning of clusters is an open challenge due to the lack of research on the clustering of the machinery health monitoring data. This dissertation uses unimodality of the data as a criterion for clustering validation, and a unimodality-based clustering method is developed. Methods of this dissertation were evaluated by simulated data, benchmark data, experimental study and field data. These methods provide consistent results and outperform representatives of available methods. Although the focus of this dissertation is on the application of machinery systems, the methods developed in this dissertation can be adapted for other application scenarios for anomaly detection, feature selection, and clustering

New Methods for Structural Health Monitoring and Damage Localization

Structural Health Monitoring (SHM) is traditionally concerned with fitting sensors inside structural systems and analyzing the features of signals from the sensor measurements using appropriate signal processing techniques in order to reveal the systems’ health status. A significant change of signal features is often considered to be an indication of damage. However, generally speaking, these techniques often cannot distinguish normal structural changes due to variations in system environmental or operating conditions from the changes which are induced by damage. For example, transmissibility analysis is a widely used signal analysis method for SHM. But traditional transmissibility is determined by the ratio of the spectra of two different system outputs, which generally depends on the location of loadings on the system and is, consequently, affected by system environmental conditions. In order to solve this challenge, a series of studies are conducted in this PhD project. The objectives are to develop new SHM and damage localization methods, which can effectively address the effects of changing system environmental or operational conditions and have potential to be applied in practice to more effectively solve practical SHM and damage localization problems. First, a general baseline model based SHM method is developed in this thesis. This method can be used to address a wide class of SHM problems via a baseline modelling and baseline model based analysis. The method can systematically take the effects of system’s operating or environmental conditions such as, e.g., environmental temperature etc. on signal analysis into account, and can therefore solve relevant challenges. Both simulation studies and field data analyses have been conducted to demonstrate the performance of the proposed new technique. Moreover, new transmissibility analysis methods are proposed for the detection and location of damage with nonlinear features in Multi-Degree-Of-Freedom (MDOF) structural systems. These methods extend the traditional transmissibility analysis to the nonlinear case. More importantly, the methods are independent from the locations of loading inputs to the systems and, to a great extent, provide effective solutions to the above mentioned problems with traditional transmissibility analysis. Again both numerical simulation studies and experimental data analysis have been conducted to verify the effectiveness and demonstrate potential practical applications of the new methods. Based on the results of nonlinearity detection and localization, new guidelines are proposed for the application of transmissibility analysis based modal identification method to nonlinear structural systems, which have potential to be further developed into a new approach to transmissibility based nonlinear modal analysis. In summary, the present study has addressed a series of fundamental problems with SHM, especially, problems associated with how to deal with the effects of changing system environmental or operational conditions on SHM results. Experimental studies have demonstrated the potential and significance of these results in practical engineering applications

Data driven discovery of cyber physical systems

Cyber-physical systems embed software into the physical world. They appear in a wide range of applications such as smart grids, robotics, and intelligent manufacturing. Cyber-physical systems have proved resistant to modeling due to their intrinsic complexity arising from the combination of physical and cyber components and the interaction between them. This study proposes a general framework for discovering cyber-physical systems directly from data. The framework involves the identification of physical systems as well as the inference of transition logics. It has been applied successfully to a number of real-world examples. The novel framework seeks to understand the underlying mechanism of cyber-physical systems as well as make predictions concerning their state trajectories based on the discovered models. Such information has been proven essential for the assessment of the performance of cyber- physical systems; it can potentially help debug in the implementation procedure and guide the redesign to achieve the required performance

Development of new fault detection methods for rotating machines (roller bearings)

Abstract Early fault diagnosis of roller bearings is extremely important for rotating machines, especially for high speed, automatic and precise machines. Many research efforts have been focused on fault diagnosis and detection of roller bearings, since they constitute one the most important elements of rotating machinery. In this study a combination method is proposed for early damage detection of roller bearing. Wavelet packet transform (WPT) is applied to the collected data for denoising and the resulting clean data are break-down into some elementary components called Intrinsic mode functions (IMFs) using Ensemble empirical mode decomposition (EEMD) method. The normalized energy of three first IMFs are used as input for Support vector machine (SVM) to recognize whether signals are sorting out from healthy or faulty bearings. Then, since there is no robust guide to determine amplitude of added noise in EEMD technique, a new Performance improved EEMD (PIEEMD) is proposed to determine the appropriate value of added noise. A novel feature extraction method is also proposed for detecting small size defect using Teager-Kaiser energy operator (TKEO). TKEO is applied to IMFs obtained to create new feature vectors as input data for one-class SVM. The results of applying the method to acceleration signals collected from an experimental bearing test rig demonstrated that the method can be successfully used for early damage detection of roller bearings. Most of the diagnostic methods that have been developed up to now can be applied for the case stationary working conditions only (constant speed and load). However, bearings often work at time-varying conditions such as wind turbine supporting bearings, mining excavator bearings, vehicles, robots and all processes with run-up and run-down transients. Damage identification for bearings working under non-stationary operating conditions, especially for early/small defects, requires the use of appropriate techniques, which are generally different from those used for the case of stationary conditions, in order to extract fault-sensitive features which are at the same time insensitive to operational condition variations. Some methods have been proposed for damage detection of bearings working under time-varying speed conditions. However, their application might increase the instrumentation cost because of providing a phase reference signal. Furthermore, some methods such as order tracking methods still can be applied when the speed variation is limited. In this study, a novel combined method based on cointegration is proposed for the development of fault features which are sensitive to the presence of defects while in the same time they are insensitive to changes in the operational conditions. It does not require any additional measurements and can identify defects even for considerable speed variations. The signals acquired during run-up condition are decomposed into IMFs using the performance improved EEMD method. Then, the cointegration method is applied to the intrinsic mode functions to extract stationary residuals. The feature vectors are created by applying the Teager-Kaiser energy operator to the obtained stationary residuals. Finally, the feature vectors of the healthy bearing signals are utilized to construct a separating hyperplane using one-class support vector machine. Eventually the proposed method was applied to vibration signals measured on an experimental bearing test rig. The results verified that the method can successfully distinguish between healthy and faulty bearings even if the shaft speed changes dramatically

A World-Class University-Industry Consortium for Wind Energy Research, Education, and Workforce Development: Final Technical Report

During the two-year project period, the consortium members have developed control algorithms for enhancing the reliability of wind turbine components. The consortium members have developed advanced operation and planning tools for accommodating the high penetration of variable wind energy. The consortium members have developed extensive education and research programs for educating the stakeholders on critical issues related to the wind energy research and development. In summary, The Consortium procured one utility-grade wind unit and two small wind units. Specifically, the Consortium procured a 1.5MW GE wind unit by working with the world leading wind energy developer, Invenergy, which is headquartered in Chicago, in September 2010. The Consortium also installed advanced instrumentation on the turbine and performed relevant turbine reliability studies. The site for the wind unit is InvenergyÃÂÃÂÃÂâÃÂÃÂÃÂÃÂÃÂÃÂÃÂÃÂs Grand Ridge wind farmin Illinois. The Consortium, by working with Viryd Technologies, installed an 8kW Viryd wind unit (the Lab Unit) at an engineering lab at IIT in September 2010 and an 8kW Viryd wind unit (the Field Unit) at the Stuart Field on IITÃÂÃÂÃÂâÃÂÃÂÃÂÃÂÃÂÃÂÃÂÃÂs main campus in July 2011, and performed relevant turbine reliability studies. The operation of the Field Unit is also monitored by the Phasor Measurement Unit (PMU) in the nearby Stuart Building. The Consortium commemorated the installations at the July 20, 2011 ribbon-cutting ceremony. The ConsortiumÃÂÃÂÃÂâÃÂÃÂÃÂÃÂÃÂÃÂÃÂÃÂs researches on turbine reliability included (1) Predictive Analytics to Improve Wind Turbine Reliability; (2) Improve Wind Turbine Power Output and Reduce Dynamic Stress Loading Through Advanced Wind Sensing Technology; (3) Use High Magnetic Density Turbine Generator as Non-rare Earth Power Dense Alternative; (4) Survivable Operation of Three Phase AC Drives in Wind Generator Systems; (5) Localization of Wind Turbine Noise Sources Using a Compact Microphone Array; (6) Wind Turbine Acoustics - Numerical Studies; and (7) Performance of Wind Turbines in Rainy Conditions. The ConsortiumÃÂÃÂÃÂâÃÂÃÂÃÂÃÂÃÂÃÂÃÂÃÂs researches on wind integration included (1) Analysis of 2030 Large-Scale Wind Energy Integration in the Eastern Interconnection; (2) Large-scale Analysis of 2018 Wind Energy Integration in the Eastern U.S. Interconnection; (3) Integration of Non-dispatchable Resources in Electricity Markets; (4) Integration of Wind Unit with Microgrid. The ConsortiumÃÂÃÂÃÂâÃÂÃÂÃÂÃÂÃÂÃÂÃÂÃÂs education and outreach activities on wind energy included (1) Wind Energy Training Facility Development; (2) Wind Energy Course Development; (3) Wind Energy Outreach

Advanced Fault Diagnosis and Health Monitoring Techniques for Complex Engineering Systems

Over the last few decades, the field of fault diagnostics and structural health management has been experiencing rapid developments. The reliability, availability, and safety of engineering systems can be significantly improved by implementing multifaceted strategies of in situ diagnostics and prognostics. With the development of intelligence algorithms, smart sensors, and advanced data collection and modeling techniques, this challenging research area has been receiving ever-increasing attention in both fundamental research and engineering applications. This has been strongly supported by the extensive applications ranging from aerospace, automotive, transport, manufacturing, and processing industries to defense and infrastructure industries

Design of an intelligent embedded system for condition monitoring of an industrial robot

PhD ThesisIndustrial robots have long been used in production systems in order to improve productivity, quality and safety in automated manufacturing processes. There are significant implications for operator safety in the event of a robot malfunction or failure, and an unforeseen robot stoppage, due to different reasons, has the potential to cause an interruption in the entire production line, resulting in economic and production losses. Condition monitoring (CM) is a type of maintenance inspection technique by which an operational asset is monitored and the data obtained is analysed to detect signs of degradation, diagnose the causes of faults and thus reduce maintenance costs. So, the main focus of this research is to design and develop an online, intelligent CM system based on wireless embedded technology to detect and diagnose the most common faults in the transmission systems (gears and bearings) of the industrial robot joints using vibration signal analysis. To this end an old, but operational, PUMA 560 robot was utilized to synthesize a number of different transmission faults in one of the joints (3 - elbow), such as backlash between the gear pair, gear tooth and bearing faults. A two-stage condition monitoring algorithm is proposed for robot health assessment, incorporating fault detection and fault diagnosis. Signal processing techniques play a significant role in building any condition monitoring system, in order to determine fault-symptom relationships, and detect abnormalities in robot health. Fault detection stage is based on time-domain signal analysis and a statistical control chart (SCC) technique. For accurate fault diagnosis in the second stage, a novel implementation of a time-frequency signal analysis technique based on the discrete wavelet transform (DWT) is adopted. In this technique, vibration signals are decomposed into eight levels of wavelet coefficients and statistical features, such as standard deviation, kurtosis and skewness, are obtained at each level and analysed to extract the most salient feature related to faults; the artificial neural network (ANN) is then used for fault classification. A data acquisition system based on National Instruments (NI) software and hardware was initially developed for preliminary robot vibration analysis and feature extraction. The transmission faults induced in the robot can change the captured vibration spectra, and the robot’s natural frequencies were established using experimental modal analysis, and also the fundamental fault frequencies for the gear transmission and bearings were obtained and utilized for preliminary robot condition monitoring. In addition to simulation of different levels of backlash fault, gear tooth and bearing faults which have not been previously investigated in industrial robots, with several levels of ii severity, were successfully simulated and detected in the robot’s joint transmission. The vibration features extracted, which are related to the robot healthy state and different fault types, using the data acquisition system were subsequently used in building the SCC and ANN, which were trained using part of the measured data set that represents the robot operating range. Another set of data, not used within the training stage, was then utilized for validation. The results indicate the successful detection and diagnosis of faults using the key extracted parameters. A wireless embedded system based on the ZigBee communication protocol was designed for the application of the proposed CM algorithm in real-time, using an Arduino DUE as the core of the wireless sensor unit attached on the robot arm. A Texas Instruments digital signal processor (TMS320C6713 DSK board) was used as the base station of the wireless system on which the robot’s fault diagnosis algorithm is run. To implement the two stages of the proposed CM algorithm on the designed embedded system, software based on the C programming language has been developed. To demonstrate the reliability of the designed wireless CM system, experimental validations were performed, and high reliability was shown in the detection and diagnosis of several seeded faults in the robot. Optimistically, the established wireless embedded system could be envisaged for fault detection and diagnostics on any type of rotating machine, with the monitoring system realized using vibration signal analysis. Furthermore, with some modifications to the system’s hardware and software, different CM techniques such as acoustic emission (AE) analysis or motor current signature analysis (MCSA), can be applied.Iraqi government, represented by the Ministry of Higher Education and Scientific Research, the Iraqi Cultural Attaché in London, and the University of Technology in Baghda