Wavelet-Based Analysis of MCSA for Fault Detection in Electrical Machine

Early detection of irregularity in electrical machines is important because of their diversity of use in different fields. A proper fault detection scheme helps to stop the propagation of failure or limits its escalation to severe degrees, and thus it prevents unscheduled downtimes that cause loss of production and financial income. Among different modes of failures that may occur in the electrical machines, the rotor-related faults are around 20%. Successful detection of any failure in electrical machines is achieved by using a suitable condition monitoring followed by accurate signal processing techniques to extract the fault features. This article aims to present the extraction of features appearing in current signals using wavelet analysis when there is a rotor fault of eccentricity and broken rotor bar. In this respect, a brief explanation on rotor failures and different methods of condition monitoring with the purpose of rotor fault detection is provided. Then, motor current signature analysis, the fault-related features appeared in the current spectrum and wavelet transform analyses of the signal to extract these features are explained. Finally, two case studies involving the wavelet analysis of the current signal for the detection of rotor eccentricity and broken rotor bar are presented

Higher-order spectral analysis of stray flux signals for faults detection in induction motors

[EN] This work is a review of current trends in the stray flux signal processing techniques applied to the diagnosis of electrical machines. Initially, a review of the most commonly used standard methods is performed in the diagnosis of failures in induction machines and using stray flux; and then specifically it is treated and performed the algorithms based on statistical analysis using cumulants and polyspectra. In addition, the theoretical foundations of the analyzed algorithms and examples applications are shown from the practical point of view where the benefits that processing can have using HOSA and its relationship with stray flux signal analysis, are illustrated.This work has been supported by Generalitat Valenciana, Conselleria d'Educació, Cultura i Esport in the framework of the "Programa para la promoción de la investigación científica, el desarrollo tecnológico y la innovación en la Comunitat Valenciana", Subvenciones para grupos de investigación consolidables (ref: AICO/2019/224). J. Alberto Conejero is also partially supported by MEC Project MTM2016-75963-P.Iglesias Martínez, ME.; Antonino Daviu, JA.; Fernández De Córdoba, P.; Conejero, JA. (2020). Higher-order spectral analysis of stray flux signals for faults detection in induction motors. Applied Mathematics and Nonlinear Sciences. 5(2):1-14. https://doi.org/10.2478/amns.2020.1.00032S11452H. Akçay and E. Germen. 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Non invasive sensors for monitoring the efficiency of ac electrical rotating machines. Sensors, 10(8):7874–7895, 2010

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

Acoustic Condition Monitoring & Fault Diagnostics for Industrial Systems

Condition monitoring and fault diagnostics for industrial systems is required for cost reduction, maintenance scheduling, and reducing system failures. Catastrophic failure usually causes significant damage and may cause injury or fatality, making early and accurate fault diagnostics of paramount importance. Existing diagnostics can be improved by augmenting or replacing with acoustic measurements, which have proven advantages over more traditional vibration measurements including, earlier detection of emerging faults, increased diagnostic accuracy, remote sensors and easier setup and operation. However, industry adoption of acoustics remains in relative infancy due to vested confidence and reliance on existing measurement and, perceived difficulties with noise contamination and diagnostic accuracy. Researched acoustic monitoring examples typically employ specialist surface-mount transducers, signal amplification, and complex feature extraction and machine learning algorithms, focusing on noise rejection and fault classification. Usually, techniques are fine-tuned to maximise diagnostic performance for the given problem. The majority investigate mechanical fault modes, particularly Roller Element Bearings (REBs), owing to the mechanical impacts producing detectable acoustic waves. The first contribution of this project is a suitability study into the use of low-cost consumer-grade acoustic sensors for fault diagnostics of six different REB health conditions, comparing against vibration measurements. Experimental results demonstrate superior acoustic performance throughout but particularly at lower rotational speed and axial load. Additionally, inaccuracies caused by dynamic operational parameters (speed in this case), are minimised by novel multi-Support Vector Machine training. The project then expands on existing work to encompass diagnostics for a previously unreported electrical fault mode present on a Brush-Less Direct Current motor drive system. Commonly studied electrical faults, such as a broken rotor bar or squirrel cage, result from mechanical component damage artificially seeded and not spontaneous. Here, electrical fault modes are differentiated as faults caused by issues with the power supply, control system or software (not requiring mechanical damage or triggering intervention). An example studied here is a transient current instability, generated by non-linear interaction of the motor electrical parameters, parasitic components and digital controller realisation. Experimental trials successfully demonstrate real-time feature extraction and further validate consumer-grade sensors for industrial system diagnostics. Moreover, this marks the first known diagnosis of an electrically-seeded fault mode as defined in this work. Finally, approaching an industry-ready diagnostic system, the newly released PYNQ-Z2 Field Programmable Gate Array is used to implement the first known instance of multiple feature extraction algorithms that operate concurrently in continuous real-time. A proposed deep-learning algorithm can analyse the features to determine the optimum feature extraction combination for ongoing continuous monitoring. The proposed black-box, all-in-one solution, is capable of accurate unsupervised diagnostics on almost any application, maintaining excellent diagnostic performance. This marks a major leap forward from fine-tuned feature extraction performed offline for artificially seeded mechanical defects to multiple real-time feature extraction demonstrated on a spontaneous electrical fault mode with a versatile and adaptable system that is low-cost, readily available, with simple setup and operation. The presented concept represents an industry-ready all-in-one acoustic diagnostic solution, that is hoped to increase adoption of acoustic methods, greatly improving diagnostics and minimising catastrophic failures

Development of algorithms of statistical signal processing for the detection and pattern recognitionin time series. Application to the diagnosis of electrical machines and to the features extraction in Actigraphy signals

Tesis por compendio[ES] En la actualidad, el desarrollo y aplicación de algoritmos para el reconocimiento de patrones que mejoren los niveles de rendimiento, detección y procesamiento de datos en diferentes áreas del conocimiento resulta un tema de gran interés. En este contexto, y específicamente en relación con la aplicación de estos algoritmos en el monitoreo y diagnóstico de máquinas eléctricas, el uso de señales de flujo es una alternativa muy interesante para detectar las diferentes fallas. Asimismo, y en relación con el uso de señales biomédicas, es de gran interés extraer características relevantes en las señales de actigrafía para la identificación de patrones que pueden estar asociados con una patología específica. En esta tesis, se han desarrollado y aplicado algoritmos basados en el procesamiento estadístico y espectral de señales, para la detección y diagnóstico de fallas en máquinas eléctricas, así como su aplicación al tratamiento de señales de actigrafía. Con el desarrollo de los algoritmos propuestos, se pretende tener un sistema dinámico de indicación e identificación para detectar la falla o la patología asociada que no depende de parámetros o información externa que pueda condicionar los resultados, sólo de la información primaria que inicialmente presenta la señal a tratar (como la periodicidad, amplitud, frecuencia y fase de la muestra). A partir del uso de los algoritmos desarrollados para la detección y diagnóstico de fallas en máquinas eléctricas, basados en el procesamiento estadístico y espectral de señales, se pretende avanzar, en relación con los modelos actualmente existentes, en la identificación de fallas mediante el uso de señales de flujo. Además, y por otro lado, mediante el uso de estadísticas de orden superior, para la extracción de anomalías en las señales de actigrafía, se han encontrado parámetros alternativos para la identificación de procesos que pueden estar relacionados con patologías específicas.[CA] En l'actualitat, el desenvolupament i aplicació d'algoritmes per al reconeixement de patrons que milloren els nivells de rendiment, detecció i processament de dades en diferents àrees del coneixement és un tema de gran interés. En aquest context, i específicament en relació amb l'aplicació d'aquests algoritmes a la monitorització i diagnòstic de màquines elèctriques, l'ús de senyals de flux és una alternativa molt interessant per tal de detectar les diferents avaries. Així mateix, i en relació amb l'ús de senyals biomèdics, és de gran interés extraure característiques rellevants en els senyals d'actigrafia per a la identificació de patrons que poden estar associats amb una patologia específica. En aquesta tesi, s'han desenvolupat i aplicat algoritmes basats en el processament estadístic i espectral de senyals per a la detecció i diagnòstic d'avaries en màquines elèctriques, així com la seua aplicació al tractament de senyals d'actigrafia. Amb el desenvolupament dels algoritmes proposats, es pretén obtindre un sistema dinàmic d'indicació i identificació per a detectar l'avaria o la patologia associada, el qual no depenga de paràmetres o informació externa que puga condicionar els resultats, només de la informació primària que inicialment presenta el senyal a tractar (com la periodicitat, amplitud, freqüència i fase de la mostra). A partir de l'ús dels algoritmes desenvolupats per a la detecció i diagnòstic d'avaries en màquines elèctriques, basats en el processament estadístic i espectral de senyals, es pretén avançar, en relació amb els models actualment existents, en la identificació de avaries mitjançant l'ús de senyals de flux. A més, i d'altra banda, mitjançant l'ús d'estadístics d'ordre superior, per a l'extracció d'anomalies en els senyals d'actigrafía, s'han trobat paràmetres alternatius per a la identificació de processos que poden estar relacionats amb patologies específiques.[EN] Nowadays, the development and application of algorithms for pattern recognition that improve the levels of performance, detection and data processing in different areas of knowledge is a topic of great interest. In this context, and specifically in relation to the application of these algorithms to the monitoring and diagnosis of electrical machines, the use of stray flux signals is a very interesting alternative to detect the different faults. Likewise, and in relation to the use of biomedical signals, it is of great interest to extract relevant features in actigraphy signals for the identification of patterns that may be associated with a specific pathology. In this thesis, algorithms based on statistical and spectral signal processing have been developed and applied to the detection and diagnosis of failures in electrical machines, as well as to the treatment of actigraphy signals. With the development of the proposed algorithms, it is intended to have a dynamic indication and identification system for detecting the failure or associated pathology that does not depend on parameters or external information that may condition the results, but only rely on the primary information that initially presents the signal to be treated (such as the periodicity, amplitude, frequency and phase of the sample). From the use of the algorithms developed for the detection and diagnosis of failures in electrical machines, based on the statistical and spectral signal processing, it is intended to advance, in relation to the models currently existing, in the identification of failures through the use of stray flux signals. In addition, and on the other hand, through the use of higher order statistics for the extraction of anomalies in actigraphy signals, alternative parameters have been found for the identification of processes that may be related to specific pathologies.Iglesias Martínez, ME. (2020). Development of algorithms of statistical signal processing for the detection and pattern recognitionin time series. Application to the diagnosis of electrical machines and to the features extraction in Actigraphy signals [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/145603TESISCompendi

Modelling and detection of faults in axial-flux permanent magnet machines

The development of various topologies and configurations of axial-flux permanent magnet machine has spurred its use for electromechanical energy conversion in several applications. As it becomes increasingly deployed, effective condition monitoring built on reliable and accurate fault detection techniques is needed to ensure its engineering integrity. Unlike induction machine which has been rigorously investigated for faults, axial-flux permanent magnet machine has not. Thus in this thesis, axial-flux permanent magnet machine is investigated under faulty conditions. Common faults associated with it namely; static eccentricity and interturn short circuit are modelled, and detection techniques are established. The modelling forms a basis for; developing a platform for precise fault replication on a developed experimental test-rig, predicting and analysing fault signatures using both finite element analysis and experimental analysis. In the detection, the motor current signature analysis, vibration analysis and electrical impedance spectroscopy are applied. Attention is paid to fault-feature extraction and fault discrimination. Using both frequency and time-frequency techniques, features are tracked in the line current under steady-state and transient conditions respectively. Results obtained provide rich information on the pattern of fault harmonics. Parametric spectral estimation is also explored as an alternative to the Fourier transform in the steady-state analysis of faulty conditions. It is found to be as effective as the Fourier transform and more amenable to short signal-measurement duration. Vibration analysis is applied in the detection of eccentricities; its efficacy in fault detection is hinged on proper determination of vibratory frequencies and quantification of corresponding tones. This is achieved using analytical formulations and signal processing techniques. Furthermore, the developed fault model is used to assess the influence of cogging torque minimization techniques and rotor topologies in axial-flux permanent magnet machine on current signal in the presence of static eccentricity. The double-sided topology is found to be tolerant to the presence of static eccentricity unlike the single-sided topology due to the opposing effect of the resulting asymmetrical properties of the airgap. The cogging torque minimization techniques do not impair on the established fault detection technique in the single-sided topology. By applying electrical broadband impedance spectroscopy, interturn faults are diagnosed; a high frequency winding model is developed to analyse the impedance-frequency response obtained

Condition Monitoring of a Belt-Based Transmission System for Comau Racer3 Robots

This project has been developed in collaboration with Comau Robotics S.p.a and the main goal is the development in China of an Health Monitoring Pro-cess using vibration analysis. This project is connected to the activity of Cost Reduction carried out by the PD Cost Engineering Department in China. The Project is divided in two part: 1. Data Acquisition 2. Data Analysis An Automatic Acquisition of the moni.log file is carried out and is discussed in Chapter 1. As for the Data Analysis is concerned a data driven approach is considered and developed in frequency domain through the FFT transform and in time domain using the Wavelet transform. In Chapter 2 a list of the techiques used nowadays for the Signal Analysis and the Vibration Monitoring is shown in time domain, frequency domain and time-frequency domain. In Chapter 3 the state of art of the Condition Monitoring of all the possible ma-chinery part is carried out from the evaluation of the spectrum of the current and speed. In Chapter 4 are evaluated disturbances that are not related to a fault but be-long to a normal behaviour of the system acting on the measured forces. Motor Torque Ripple and Output Noise Resolution are disturbance dependent on ve-locity and are mentioned in comparison to the one related to the configuration of the Robot. In Chapter 5 a particular study case is assigned: the noise problem due to belt-based power transmission system of the axis three of a Racer 3 Robot in Endu-rance test. The chapter presents the test plan done including all the simula-tions. In Chapter 6 all the results are shown demostrating how the vibration analysis carried out from an external sensor can be confirmed looking at the spectral content of the speed and the current. In the last Chapter the final conclusions and a possible development of this thesis are presented considering both a a Model of Signal and a Model Based approach

Fault diagnosis of motorized spindle via modified empirical wavelet transform-kernel PCA and optimized support vector machine

The fault diagnosis of motorized spindle contributes to the improvement of the reliability of computer numerical control machine tools. Presently, numerous mechanical fault diagnosis technologies suffer from the drawbacks of mode mixing, non-adaptive analysis, and low efficiency. Therefore, adopting an effective signal processing method for fault diagnosis of motorized spindle is essential. A method based on modified empirical wavelet transform (EWT) and kernel principal component analysis (Kernel PCA) is proposed. A new method, which determines the proper number of the Fourier spectrum segments, is applied when using EWT. To improve computational efficiency, Kernel PCA is adopted to reduce dimension. The support vector machine optimized by genetic algorithm is introduced to accomplish fault identification. The performance of the proposed method is validated through single and compound fault experiments. Results show that the recognition rate using the proposed method reached 98.8095 % and 98.4375 % in terms of single and compound fault diagnoses, respectively. Moreover, compared with empirical mode decomposition (EMD), ensemble empirical mode decomposition (EEMD), local mean decomposition (LMD) and EWT, the proposed method can save much computing time. The proposed method can be generalized to other mechanical fault diagnoses as well

ROBUST FAULT ANALYSIS FOR PERMANENT MAGNET DC MOTOR IN SAFETY CRITICAL APPLICATIONS

Robust fault analysis (FA) including the diagnosis of faults and predicting their level of severity is necessary to optimise maintenance and improve reliability of Aircraft. Early diagnosis of faults that might occur in the supervised process renders it possible to perform important preventative actions. The proposed diagnostic models were validated in two experimental tests. The first test concerned a single localised and generalised roller element bearing fault in a permanent magnet brushless DC (PMBLDC) motor. Rolling element bearing defect is one of the main reasons for breakdown in electrical machines. Vibration and current are analysed under stationary and non-stationary load and speed conditions, for a variety of bearing fault severities, and for both local and global bearing faults. The second test examined the case of an unbalance rotor due to blade faults in a thruster, motor based on a permanent magnet brushed DC (PMBDC) motor. A variety of blade fault conditions were investigated, over a wide range of rotation speeds. The test used both discrete wavelet transform (DWT) to extract the useful features, and then feature reduction techniques to avoid redundant features. This reduces computation requirements and the time taken for classification by the application of an orthogonal fuzzy neighbourhood discriminant analysis (OFNDA) approach. The real time monitoring of motor operating conditions is an advanced technique that presents the real performance of the motor, so that the dynamic recurrent neural network (DRNN) proposed predicts the conditions of components and classifies the different faults under different operating conditions. The results obtained from real time simulation demonstrate the effectiveness and reliability of the proposed methodology in accurately classifying faults and predicting levels of fault severity.the Iraqi Ministry of Higher Education and Scientific Researc