Real-Time Fault Diagnosis of Permanent Magnet Synchronous Motor and Drive System

Permanent Magnet Synchronous Motors (PMSMs) have gained massive popularity in industrial applications such as electric vehicles, robotic systems, and offshore industries due to their merits of efficiency, power density, and controllability. PMSMs working in such applications are constantly exposed to electrical, thermal, and mechanical stresses, resulting in different faults such as electrical, mechanical, and magnetic faults. These faults may lead to efficiency reduction, excessive heat, and even catastrophic system breakdown if not diagnosed in time. Therefore, developing methods for real-time condition monitoring and detection of faults at early stages can substantially lower maintenance costs, downtime of the system, and productivity loss. In this dissertation, condition monitoring and detection of the three most common faults in PMSMs and drive systems, namely inter-turn short circuit, demagnetization, and sensor faults are studied. First, modeling and detection of inter-turn short circuit fault is investigated by proposing one FEM-based model, and one analytical model. In these two models, efforts are made to extract either fault indicators or adjustments for being used in combination with more complex detection methods. Subsequently, a systematic fault diagnosis of PMSM and drive system containing multiple faults based on structural analysis is presented. After implementing structural analysis and obtaining the redundant part of the PMSM and drive system, several sequential residuals are designed and implemented based on the fault terms that appear in each of the redundant sets to detect and isolate the studied faults which are applied at different time intervals. Finally, real-time detection of faults in PMSMs and drive systems by using a powerful statistical signal-processing detector such as generalized likelihood ratio test is investigated. By using generalized likelihood ratio test, a threshold was obtained based on choosing the probability of a false alarm and the probability of detection for each detector based on which decision was made to indicate the presence of the studied faults. To improve the detection and recovery delay time, a recursive cumulative GLRT with an adaptive threshold algorithm is implemented. As a result, a more processed fault indicator is achieved by this recursive algorithm that is compared to an arbitrary threshold, and a decision is made in real-time performance. The experimental results show that the statistical detector is able to efficiently detect all the unexpected faults in the presence of unknown noise and without experiencing any false alarm, proving the effectiveness of this diagnostic approach.publishedVersio

Learning for predictions: Real-time reliability assessment of aerospace systems

Prognostics and Health Management (PHM) aim to predict the Remaining Useful Life (RUL) of a system and to allow a timely planning of replacement of components, limiting the need for corrective maintenance and the down time of equipment. A major challenge in system prognostics is the availability of accurate physics based representations of the grow rate of faults. Additionally, the analysis of data acquired during flight operations is traditionally time consuming and expensive. This work proposes a computational method to overcome these limitations through the dynamic adaptation of the state-space model of fault propagation to on-board observations of system’s health. Our approach aims at enabling real-time assessment of systems health and reliability through fast predictions of the Remaining Useful Life that account for uncertainty. The strategy combines physics-based knowledge of the system damage propagation rate, machine learning and real-time measurements of the health status to obtain an accurate estimate of the RUL of aerospace systems. The RUL prediction algorithm relies on a dynamical estimator filter, which allows to deal with nonlinear systems affected by uncertainties with unknown distribution. The proposed method integrates a dynamical model of the fault propagation, accounting for the current and past measured health conditions, the past time history of the operating conditions (such as input command, load, temperature, etc.), and the expected future operating conditions. The model leverages the knowledge collected through the record of past fault measurements, and dynamically adapts the prediction of the damage propagation by learning from the observed time history. The original method is demonstrated for the RUL prediction of an electromechanical actuator for aircraft flight controls. We observe that the strategy allows to refine rapid predictions of the RUL in fractions of seconds by progressively learning from on-board acquisitions

A hybrid intelligent technique for induction motor condition monitoring

The objective of this research is to advance the field of condition monitoring and fault diagnosis for induction motors. This involves processing the signals produced by induction motors, classifying the types and estimating the severity of induction motors faults. A typical process of condition monitoring and fault diagnosis for induction motors consists of four steps: data acquisition, signal analysis, fault detection and post-processing. A description of various kinds of faults that can occur in induction motors is presented. The features reflecting faults are usually embedded in transient motor signals. The signal analysis is a very important step in the motor fault diagnosis process, which is to extract features which are related to specific fault modes. The signal analysis methods available in feature extraction for motor signals are discussed. The wavelet packet decomposition results consist of the time-frequency representation of a signal in the same time, which is inherently suited to the transient events in the motor fault signals. The wavelet packet transform-based analysis method is proposed to extract the features of motor signals. Fault detection has to establish a relationship between the motor symptoms and the condition. Classifying motor condition and estimating the severity of faults from the motor signals have never been easy tasks and they are affected by many factors. AI techniques, such as expert system (ES), fuzzy logic system (FLS), artificial neural network (ANN) and support vector machine (SVM), have been applied in fault diagnosis of very complex system, where accurate mathematical models are difficult to be built. These techniques use association, reasoning and decision making processes as would the human brain in solving diagnostic problems. ANN is a computation and information processing method that mimics the process found in biological neurons. But when ANN-based methods are used for fault diagnosis, local minimums caused by the traditional training algorithms often result in large approximation error that may destroy their reliability. In this research, a novel method of condition monitoring and fault diagnosis for induction motor is proposed using hybrid intelligent techniques based on WPT. ANN is trained by improved genetic algorithm (IGA). WPT is used to decompose motor signals to extract the feature parameters. The extracted features with different frequency resolutions are used as the input of ANN for the fault diagnosis. Finally, the proposed method is tested in 1.5 kW and 3.7 kW induction motor rigs. The experimental results demonstrate that the proposed method improves the sensitivity and accuracy of the ANN-based methods of condition monitoring and fault diagnosis for induction motors.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Automatic Fault Diagnostic System for Induction Motors under Transient Regime Optimized with Expert Systems

[EN] Induction machines (IMs) power most modern industrial processes (induction motors) and generate an increasing portion of our electricity (doubly fed induction generators). A continuous monitoring of the machine's condition can identify faults at an early stage, and it can avoid costly, unexpected shutdowns of production processes, with economic losses well beyond the cost of the machine itself. Machine current signature analysis (MCSA), has become a prominent technique for condition-based maintenance, because, in its basic approach, it is non-invasive, requires just a current sensor, and can process the current signal using a standard fast Fourier transform (FFT). Nevertheless, the industrial application of MCSA requires well-trained maintenance personnel, able to interpret the current spectra and to avoid false diagnostics that can appear due to electrical noise in harsh industrial environments. This task faces increasing difficulties, especially when dealing with machines that work under non-stationary conditions, such as wind generators under variable wind regime, or motors fed from variable speed drives. In these cases, the resulting spectra are no longer simple one-dimensional plots in the time domain; instead, they become two-dimensional images in the joint time-frequency domain, requiring highly specialized personnel to evaluate the machine condition. To alleviate these problems, supporting the maintenance staff in their decision process, and simplifying the correct use of fault diagnosis systems, expert systems based on neural networks have been proposed for automatic fault diagnosis. However, all these systems, up to the best knowledge of the authors, operate under steady-state conditions, and are not applicable in a transient regime. To solve this problem, this paper presents an automatic system for generating optimized expert diagnostic systems for fault detection when the machine works under transient conditions. The proposed method is first theoretically introduced, and then it is applied to the experimental diagnosis of broken bars in a commercial cage induction motor.Burriel-Valencia, J.; Puche-Panadero, R.; Martinez-Roman, J.; Sapena-Bano, A.; Pineda-Sanchez, M.; Pérez-Cruz, J.; Riera-Guasp, M. (2019). Automatic Fault Diagnostic System for Induction Motors under Transient Regime Optimized with Expert Systems. Electronics. 8(1):1-16. https://doi.org/10.3390/electronics8010006S11681Puche-Panadero, R., Pineda-Sanchez, M., Riera-Guasp, M., Roger-Folch, J., Hurtado-Perez, E., & Perez-Cruz, J. (2009). Improved Resolution of the MCSA Method Via Hilbert Transform, Enabling the Diagnosis of Rotor Asymmetries at Very Low Slip. IEEE Transactions on Energy Conversion, 24(1), 52-59. doi:10.1109/tec.2008.2003207Abd-el -Malek, M., Abdelsalam, A. K., & Hassan, O. E. (2017). Induction motor broken rotor bar fault location detection through envelope analysis of start-up current using Hilbert transform. Mechanical Systems and Signal Processing, 93, 332-350. doi:10.1016/j.ymssp.2017.02.014Martinez, J., Belahcen, A., & Muetze, A. (2017). Analysis of the Vibration Magnitude of an Induction Motor With Different Numbers of Broken Bars. IEEE Transactions on Industry Applications, 53(3), 2711-2720. doi:10.1109/tia.2017.2657478Sapena-Bano, A., Pineda-Sanchez, M., Puche-Panadero, R., Perez-Cruz, J., Roger-Folch, J., Riera-Guasp, M., & Martinez-Roman, J. (2015). Harmonic Order Tracking Analysis: A Novel Method for Fault Diagnosis in Induction Machines. IEEE Transactions on Energy Conversion, 30(3), 833-841. doi:10.1109/tec.2015.2416973Sapena-Bano, A., Burriel-Valencia, J., Pineda-Sanchez, M., Puche-Panadero, R., & Riera-Guasp, M. (2017). The Harmonic Order Tracking Analysis Method for the Fault Diagnosis in Induction Motors Under Time-Varying Conditions. IEEE Transactions on Energy Conversion, 32(1), 244-256. doi:10.1109/tec.2016.2626008Burriel-Valencia, J., Puche-Panadero, R., Martinez-Roman, J., Sapena-Bano, A., & Pineda-Sanchez, M. (2017). Short-Frequency Fourier Transform for Fault Diagnosis of Induction Machines Working in Transient Regime. IEEE Transactions on Instrumentation and Measurement, 66(3), 432-440. doi:10.1109/tim.2016.2647458Yin, Z., & Hou, J. (2016). Recent advances on SVM based fault diagnosis and process monitoring in complicated industrial processes. Neurocomputing, 174, 643-650. doi:10.1016/j.neucom.2015.09.081Bazan, G. H., Scalassara, P. R., Endo, W., Goedtel, A., Godoy, W. F., & Palácios, R. H. C. (2017). Stator fault analysis of three-phase induction motors using information measures and artificial neural networks. Electric Power Systems Research, 143, 347-356. doi:10.1016/j.epsr.2016.09.031Mustafidah, H., Hartati, S., Wardoyo, R., & Harjoko, A. (2014). Selection of Most Appropriate Backpropagation Training Algorithm in Data Pattern Recognition. International Journal of Computer Trends and Technology, 14(2), 92-95. doi:10.14445/22312803/ijctt-v14p120Godoy, W. F., da Silva, I. N., Lopes, T. D., Goedtel, A., & Palácios, R. H. C. (2016). Application of intelligent tools to detect and classify broken rotor bars in three-phase induction motors fed by an inverter. IET Electric Power Applications, 10(5), 430-439. doi:10.1049/iet-epa.2015.0469Ghorbanian, V., & Faiz, J. (2015). A survey on time and frequency characteristics of induction motors with broken rotor bars in line-start and inverter-fed modes. Mechanical Systems and Signal Processing, 54-55, 427-456. doi:10.1016/j.ymssp.2014.08.022Valles-Novo, R., de Jesus Rangel-Magdaleno, J., Ramirez-Cortes, J. M., Peregrina-Barreto, H., & Morales-Caporal, R. (2015). Empirical Mode Decomposition Analysis for Broken-Bar Detection on Squirrel Cage Induction Motors. IEEE Transactions on Instrumentation and Measurement, 64(5), 1118-1128. doi:10.1109/tim.2014.2373513De Santiago-Perez, J. J., Rivera-Guillen, J. R., Amezquita-Sanchez, J. P., Valtierra-Rodriguez, M., Romero-Troncoso, R. J., & Dominguez-Gonzalez, A. (2018). Fourier transform and image processing for automatic detection of broken rotor bars in induction motors. Measurement Science and Technology, 29(9), 095008. doi:10.1088/1361-6501/aad3aaMerabet, H., Bahi, T., Drici, D., Halam, N., & Bedoud, K. (2017). Diagnosis of rotor fault using neuro-fuzzy inference system. Journal of Fundamental and Applied Sciences, 9(1), 170. doi:10.4314/jfas.v9i1.12Riera-Guasp, M., Pineda-Sanchez, M., Perez-Cruz, J., Puche-Panadero, R., Roger-Folch, J., & Antonino-Daviu, J. A. (2012). Diagnosis of Induction Motor Faults via Gabor Analysis of the Current in Transient Regime. IEEE Transactions on Instrumentation and Measurement, 61(6), 1583-1596. doi:10.1109/tim.2012.2186650Gyftakis, K. N., Marques Cardoso, A. J., & Antonino-Daviu, J. A. (2017). Introducing the Filtered Park’s and Filtered Extended Park’s Vector Approach to detect broken rotor bars in induction motors independently from the rotor slots number. Mechanical Systems and Signal Processing, 93, 30-50. doi:10.1016/j.ymssp.2017.01.04

Modelling and Detecting Faults of Permanent Magnet Synchronous Motors in Dynamic Operations

Paper VI is excluded from the dissertation until the article will be published.Permanent magnet synchronous motors (PMSMs) have played a key role in commercial and industrial applications, i.e. electric vehicles and wind turbines. They are popular due to their high efficiency, control simplification and large torque-to-size ratio although they are expensive. A fault will eventually occur in an operating PMSM, either by improper maintenance or wear from thermal and mechanical stresses. The most frequent PMSM faults are bearing faults, short-circuit and eccentricity. PMSM may also suffer from demagnetisation, which is unique in permanent magnet machines. Condition monitoring or fault diagnosis schemes are necessary for detecting and identifying these faults early in their incipient state, e.g. partial demagnetisation and inter-turn short circuit. Successful fault classification will ensure safe operations, speed up the maintenance process and decrease unexpected downtime and cost. The research in recent years is drawn towards fault analysis under dynamic operating conditions, i.e. variable load and speed. Most of these techniques have focused on the use of voltage, current and torque, while magnetic flux density in the air-gap or the proximity of the motor has not yet been fully capitalised. This dissertation focuses on two main research topics in modelling and diagnosis of faulty PMSM in dynamic operations. The first problem is to decrease the computational burden of modelling and analysis techniques. The first contributions are new and faster methods for computing the permeance network model and quadratic time-frequency distributions. Reducing their computational burden makes them more attractive in analysis or fault diagnosis. The second contribution is to expand the model description of a simpler model. This can be achieved through a field reconstruction model with a magnet library and a description of both magnet defects and inter-turn short circuits. The second research topic is to simplify the installation and complexity of fault diagnosis schemes in PMSM. The aim is to reduce required sensors of fault diagnosis schemes, regardless of operation profiles. Conventional methods often rely on either steady-state or predefined operation profiles, e.g. start-up. A fault diagnosis scheme robust to any speed changes is desirable since a fault can be detected regardless of operations. The final contribution is the implementation of reinforcement learning in an active learning scheme to address the imbalance dataset problem. Samples from a faulty PMSM are often initially unavailable and expensive to acquire. Reinforcement learning with a weighted reward function might balance the dataset to enhance the trained fault classifier’s performance.publishedVersio

An investigation into current and vibration signatures of three phase induction motors

This research aimed at investigating the relationship between three phase induction motors vibration (MVS) and current signatures (MCS). This is essential due to the cost of vibration measuring equipment and in cases where vibration of interest point is not accessible; such as electrical submersible pumps (ESP) used in oil industry. A mathematical model was developed to understand the effects of two types of induction motors common faults; rotor bar imperfections and phase imbalance on the motor vibration and current signatures. An automated test facility was developed in which 1.1 kW three phase motor could be tested under varying shaft rotation speeds and loads for validating the developed model. Time and frequency domains statistical parameters of the measured signals were calculated for fault detection and assessing its severity. The measured signals were also processed using the short time Fourier transform (STFT), the Wigner-Ville distribution (WVD), the continuous wavelet transform (CWT) and discrete wavelet transform (DWT) and wavelet multi-resolution analysis (MRA). The non-stationary components, representing faults within induction motor measured vibration and current signals, were successfully detected using wavelet decomposition technique. An effective alternative to direct vibration measurement scheme, based on radial basis function networks, was developed to the reconstruction of motor vibration using measurements of one phase of the motor current. It was found that this method captured the features of induction motor faults with reasonable degrees of accuracy. Another method was also developed for the early detection and diagnosis of faults using an enhanced power factor method. Experimental results confirmed that the power factor can be used successfully for induction motor fault diagnosis and is also promising in assessing fault severity. The suggested two methods offer inexpensive, reliable and non-intrusive condition monitoring tools that suits real-time applications. Directions for further work were also outlined

Size and Location Diagnosis of Rolling Bearing Faults: An Approach of Kernel Principal Component Analysis and Deep Belief Network

Diagnosing incipient faults of rotating machines is very important for reducing economic losses and avoiding accidents caused by faults. However, diagnoses of locations and sizes of incipient faults are very difficult in a noisy background. In this paper, we propose a fault diagnosis method that combines kernel principal component analysis (KPCA) and deep belief network (DBN) to detect sizes and locations of incipient faults on rolling bearings. Effective information of raw vibration signals processed by KPCA method is used as input signals of the DBN of which weights of the first RBM are initialized by contribution rates of principal components. A DBN with complex structures can be cut into a briefer network by KPCA-DBN model. That model reduces network structure and increases convergence rate. As a result, an average test accuracy by KPCA-DBN can reach 99.1% for identification of 12 labels including incipient faults and the training time is 28s which is half of that by DBN model. The average accuracy of rolling bearing location detection nearly gets to 100% and the average accuracy of fault size detection is above 99%. Compared with SVM, BP, CNN, Deep EMD-PCA (Empirical Mode Decomposition-Principal Component Analysis), CNN-SVM and DBN, it is found that training time can be shortened and detection accuracy can be improved by KPCA-DBN model. The proposed method is beneficial to realize sizes and locations detection of incipient faults online

Induction motors fault diagnosis using machine learning and advanced signal processing techniques

In this thesis, induction motors fault diagnosis are investigated using machine learning and advanced signal processing techniques considering two scenarios: 1) induction motors are directly connected online; and 2) induction motors are fed by variable frequency drives (VFDs). The research is based on experimental data obtained in the lab. Various single- and multi- electrical and/or mechanical faults were applied to two identical induction motors in experiments. Stator currents and vibration signals of the two motors were measured simultaneously during experiments and were used in developing the fault diagnosis method. Signal processing techniques such as Matching Pursuit (MP) and Discrete Wavelet Transform (DWT) are chosen for feature extraction. Classification algorithms, including decision trees, support vector machine (SVM), K-nearest neighbors (KNN), and Ensemble algorithms are used in the study to evaluate the performance and suitability of different classifiers for induction motor fault diagnosis. Novel curve or surface fitting techniques are implemented to obtain features for conditions that have not been tested in experiments. The proposed fault diagnosis method can accurately detect single- or multi- electrical and mechanical faults in induction motors either directly online or fed by VFDs. In addition to the machine learning method, a threshold method using the stator current signal processed by DWT is also proposed in the thesis