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SPEEDAM 2010 International Symposium on Power Electronics, Electrical Drives, Automation and Motion

The Intelligent Fault Diagnosis Frameworks Based on Fuzzy Integral


M. Karakse*, I. Aydin*, E. Akin*
*Firat University, Computer Engineering Department, 23119, Elazig (Turkey)

AbstractFuzzy integral is an information aggregation and combination process in a multi-criteria environment using fuzzy measures. This paper presents a new data fusion method using fuzzy integral for fault diagnosis. The method consists of two frameworks. The first framework was employed to identify the relations between features and a specified fault. The second framework was implemented to integrate different diagnosis algorithms to improve the accuracy rates of them. The choquet fuzzy integral was utilized for two frameworks. The proposed approach was experimentally implemented on a 0.37 kW induction motor. Broken rotor bar and stator faults were evaluated to validate the models. The results showed that the proposed method performs very well for broken rotor bar and stator faults. Index Terms-- Fuzzy integral, fault diagnosis, induction motors, intelligent techniques, signal processing.

I. INTRODUCTION The induction motors that present many advantages such as robustness, reliability and efficiency are widely used in industrial applications [1]. These motors are subject to many faults due to dusty and moist environments. If these faults are not detected in an early stage, the other components of the motor are damaged and the production may be completely broke down [2]. The induction motor faults are mainly occurred in three motor components: rotor, stator and bearing. Stator faults are related to stator winding open phase or short circuited. Rotor faults include open or short circuited for wound motors and broken bars or cracked end-ring for squirrel cage motors. Bearing faults consist of bearing damage, eccentricity, bent shaft, and misalignment. Some expensive maintenance techniques are performed to prevent any motor fault [3]. In recent years, the researchers have tended to inexpensive and simple maintenance techniques for electrical machines. Vibration and temperature signals have been used in order to provide new monitoring techniques in the past two decades. However, these sensors are expensive and they should be carefully mounted to the motor. The recent researchers has directed toward using electrical sensors such as current and voltage for condition monitoring [4]. The most popular fault detection method based on motor current is the motor current signature analysis (MCSA) [5]. This method is based on fast Fourier transform of one phase current. The fault related frequencies are interpreted and the faults are determined for each specified condition. This method gives efficient

results to detect rotor, stator, and bearing faults when motor is operated under strength load. However, when the motor is operated under very week or no-load condition, the method fails in detection of faults. To detect faults under no-load condition, wavelet analysis was applied to startup transient of stator current [6]. Because the startup transient current is a non-stationary signal, wavelet transform can be used to extract fault related components. Wavelet analysis was also applied to steady-state current for fault detection [7], [8]. Tsoumas et al. [7] introduced a novel wavelet based approach for fault detection in induction motors. The faults are detected using stator phase current that is filtered through a complex wavelet. Jimenez et al. [8] proposed a Hilbert transform based feature extraction to detect broken rotor bar faults. The broken bar faults were detected applying wavelet transform to this feature signal. The common characteristic of MCSA and wavelet analysis is that the fault is determined based on rotor frequency. Another feature extraction method is based on parks vector approach using three phase current signals [9]. Artificial intelligence approaches have been developed in order to automate the detection of faults [10]. The conventional fault diagnosis techniques have been recently replaced with artificial intelligence techniques which increase the generalization of the fault detection methods. Artificial intelligence based techniques cannot only classify the faults, but also identify the fault severity. Artificial neural networks do not require the mathematical model of a motor and has a flexibility to learn different conditions. With these features, supervised and unsupervised neural networks model were proposed to detect broken rotor bar [11], [12], stator [13], and bearing faults [14]. Fuzzy logic was used to detect voltage unbalance and stator faults [15]. The broken rotor bar faults were classified using support vector machines [7], [16]. In literature, some papers based on artificial intelligence methods have been applied to detect different fault types of induction motors. Each method gives an accuracy rate for a specified fault type. In this paper, two frameworks based on fuzzy integral are proposed for diagnosis of induction motor faults. First framework evaluates the importances of features in fault classification. Second framework integrates different diagnosis methods to detect broken rotor bar and stator faults in induction motors. Therefore, the accuracy of fault diagnosis can be improved. The choquet fuzzy integral theory was used to combine the features and diagnosis methods.

978-1-4244-4987-3/10/$25.00 2010 IEEE

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II. CONDITION BASED MAINTANANCE Condition-based maintenance is the use of the signals of electrical machines to determine their conditions [5]. Hence, required repairing and scheduled maintenance can be made prior to breakdown. Some definitions should be described in condition-based maintenance such as fault detection, diagnosis and prognosis. In the fault detection, it is determined whether the motor has or not any fault. The type and size of fault are not determined. On the other hand, the size and type of a fault are found in fault diagnosis. The fault prognosis is the forecasting the remained life of induction motors. The electrical machines should be monitored to insure the safety operation and protection [1]. The first condition monitoring schemes relied on simple protection methods such as over-voltage and current fuses [10]. However, these fuses do not prevent the faults in an early stage. They can only protect and notify the personnel near to the motor and the motor generally breaks down in this stage. The electrical machines should be monitored to detect the faults in an early stage. Current, voltage and vibration monitoring has been utilized for this purpose in recent years. The block diagram of the general fault diagnosis algorithms is shown in Fig.1.

III. FUZZY INTEGRAL AND FUZZY MEASURES Fuzzy integral is an aggregation tool used in order to construct the relationship between different criteria in a multi criteria environment [17]. The fuzzy measure and fuzzy integral were firstly proposed by Sugeno in 1974 to represent fuzzy systems. This method is mathematically the aggregation of two functions multiplication and can be represented as

h( x )g ( xi)
i

(1)

where h function represents an evaluation of the confidence level of information according to an xi value. Other function g can be taken as fuzzy weight factors. This function gives the importance or contribution of information source when xi value is taken into account in final evaluation. Choquet fuzzy integral is a generalized version of standard integral [18]. In this method, the function value of h(xi) are sorted in an ascending order. The x-axis represents the criteria or feature value and the confidence level of information source are given in yaxis. The Choquet fuzzy integral is defined by
CFI

(h( xi)  h( x
i 1

i 1 )).g ( x

| h( x) t hi ); h0

(2)

Fig. 1. Block diagram of fault diagnosis scheme.

In a general fault diagnosis scheme, signals are firstly acquired from the motor and then fault related features are extracted from signals in preprocessing stage. The faults are diagnosed using intelligent techniques in the last step. Because induction motors are utilized in many industrial applications, fault diagnosis schemes developed for these motors can be easily adapted to other motor types. TABLE I shows some methods for fault detection, diagnosis, and prognosis depicted in Fig. 1.
TABLE I. FAULT DIAGNOSIS METHODS Extracted Algorith Signal Preprocessing features m Transient Slip based detail Wavelet analysis SVM [7] Current frequencies Motor current Current, ANN signature Sidebands Speed [11] analysis The maximum Park vector and ANN values of two principal Current [13] park vector component components analysis Signature Frequency ANN Vibrations analysis with component [14] fourier transform amplitude Parks vector Current Severity index FL [15] component Park vector SVM Current Phase spaces transform [16] Time series Current Phase spaces AIS [20] analysis

where the values of h function should insure the hn t hn 1 t ....... ! h1 t h0 0 and each h value should be positive definition. The choquet fuzzy integral can be graphically shown in Fig. 2.

Fig. 2. Choquet fuzzy integral.

As shown in Fig. 2, all h values are positive and they are ascending order. This shows that choquet fuzzy integral is a positive definition type integral. IV. INTELLIGENT FAULT DIAGNOSIS FRAMEWORKS BASED ON FUZZY INTEGRAL The proposed fuzzy integral based intelligent fault diagnosis method consists of two frameworks. The first framework is a signal based data fusion method. It combines some features extracted from motor currents. The second framework consists of a fusion of different intelligent techniques. This framework integrates results

TABLE I shows that intelligent techniques have been combined with signal processing method to automate the diagnosis process.

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of different diagnosis algorithms for same fault types. The details of these algorithms are given in the next two subsections. A. Framework 1: The fusion of features for fault diagnosis Framework 1 utilizes some features extracted from motor current signals to establish the relation between a feature value and a given fault. A fuzzy membership based an importance factor is assigned to each feature. The membership degrees of all features are calculated using constructed membership functions. The block diagram of proposed method is given in Fig. 3.

respectively. Suppose the amplitude of line frequency is SH and the amplitude of lower and upper sideband components are SL and SU, respectively. Two features for broken rotor bar detection can be given in (4).

FB L FBU

SH  SL S H  SU

(4)

The other fault related features are extracted from one phase current signal. Mathematically, Hilbert transform of a real sequence I(t) is a convolution between original signal and 1/St as shown in (5).

HT ( I (t ))

f

f

t  W dW

I (t )

(5)

The feature signal is constructed from the absolute value of Hilbert transform on motor phase current. This feature is given in (6).
H ( I (t )) abs( 1

St

* I (t ))

(6)

Hilbert transform is applied to a determined size of phase current. This series is taken as window. Each window consists of different number of periods of the phase current. Each window size w is determined according to
w f sampling * 1 *n fs
...
(7)

Fig. 3. The block diagram of diagnosis framework1.

The block diagram represents feature-level based a general diagnosis algorithm. The signals are firstly acquired from a system and then fault related features are extracted. Fuzzy degree of each feature is calculated to indicate its effect on diagnosis algorithm. In addition, the importance factor of each feature is determined according to specified membership functions. Five features are extracted from three phase motor current signals for detection of broken rotor bar faults. The first two features are based on Fourier transform of one phase current. The spectrum of one phase current was computed by discrete Fourier transform with hanning window. This transform is mathematically expressed as
X (e jZ )

Where fsampling is sampling rate of the current signals, fs is the line frequency (50 Hz) and n is the number of periods. The feature extracted from Hilbert transform are skewness and kurtosis, and entropy. The kurtosis and skewness parameters can be computed as

F3

(H
k 1

 mH ) 4 3

4 ( w  1)V H

(8)

F4

(H
k 1

 mH ) 3

3 ( w  1)V H

(9)

I [n]w[n]e
n 0

N 1

 j Zn

(3)

where w[n] is window function and Z is the real frequency variable, and 0 d Z d 2S . The discrete time Fourier transform of I[n], is the representation of this time series in terms of a complex sequence { e  jZn }. The fault related frequencies are lower and upper sideband components, fbl (1  2 s ) f h and fbu (1  2s ) f h ,

where m H and V H represent the mean and standard deviation of each window. The last feature related to broken rotor bar fault is information entropy. (15) This feature is based on calculating the entropy between two consecutive windows. Stator faults related features are extracted from three-phase motor currents. Three features are used to evaluate the stator faults. Phase motor currents are transformed to two Parks vector components. Parks vector approach is given in (10).

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Id Iq

2 a 3 1 b 2

1 6 1 2

b c

1 6

(10)

where a, b, and c are three phase current signals and Id and Iq are two park vector components. Two features are obtained applying principal component analysis to parks vector components. The maximum values of two parks vector components are rotated on x and y axis by applying principal component analysis. The parks vector matrix will be [Id Iq] and it is denoted as X. The new Park vector components based on eigenvectors are calculated according to (11).
X0 X *v

performance of each classifier is an input of fuzzy integral. Fuzzy integral combines the diagnosis results of all diagnosis algorithms and gives one decision. The diagnosis algorithms consist of support vector machine, artificial immune system, neural network, grey clustering, and fuzzy artificial immune system. The block diagram of framework 2 is given in Fig. 5.

(11)

The maximum values of the columns of X0 are selected as features for stator fault and they called as maxId and maxIq, respectively. The stator related third feature is determined using the difference between healthy and faulty parks vector components. Fuzzy membership functions are utilized to overcome the negative effect of different feature intervals. Therefore, the inputs of each feature are in the range of [0, 1]. These membership functions and a used importance factor for a feature are given in Fig. 4.
Fig. 5. The block diagram of diagnosis framework 2.

Fig. 4. Fuzzy memberships and an importance factor.

Fig.4 shows the membership function of each feature in a faulty condition. The importance factors should cover the healthy and faulty conditions. Therefore, this factor is defined in this way. B. Framework 2: The fusion of the algorithm for fault diagnosis This framework combines different diagnosis algorithms for fault diagnosis. In this model, different features are extracted from the motor current signals. The features are firstly separated to groups. Each feature group is given to a diagnosis algorithm. The algorithms produce a performance rate for given features. The

The first diagnosis algorithm uses the neural network (NN) to diagnose broken rotor bar and stator faults. The features are extracted from three-phase current signals. The Fourier transform are applied to one phase current signal and broken rotor bar related two sideband components are obtained. Three phase current signal is used to extract stator related features. Three phase current signals are transformed to two components using parks vector transforms. The maximum values of two directions of parks vector components are obtained using principal components analysis. The feed-forward type NN is used and it has three inputs and four outputs. The same data set are also constitutes the inputs of grey clustering (GC) method. The details of these two algorithms can be seen in [19]. The second diagnosis algorithm uses support vector machines (SVM) to classify broken rotor bar faults under different feed voltage conditions. The features of this algorithm are obtained using three phase current signals. A new time series feature are formed from two park vector components obtained using three phase current signals. The phase spaces of this new time series are constructed for each motor condition. The phase spaces are classified using SVM. The details of the algorithm were given in [16]. The fourth and fifth algorithms are mainly based on artificial immune system. The fourth algorithm utilizes from negative selection algorithm that is a component of artificial immune system (AIS). The method constructs a

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V.

EXPERIMENTAL RESULTS

The experiments were performed on an actual induction motor for our analyses. The characteristics of the three-phase induction motor used in our experiment are listed in TABLE II. The motor phase currents are saved with 3 kHz sampling frequency for duration 3 seconds. The used test equipment is given in Fig. 6.
Three Phase Supply Hall-effect current sensor R Data Acquisition Card

Output of CFI

new time series using Hilbert transform of one phase current. The phase spaces of each healthy and faulty condition are constructed. The healthy and faulty phase spaces are given to negative selection algorithm and the detectors determining the faults are generated. The genetic algorithm is utilized to generate detectors with maximum coverage of non-self space. The details of this algorithm were presented in [20]. The stator and broken rotor bar faults are diagnosed using fuzzy artificial immune system (FAIS) in fifth diagnosis algorithm. This algorithm utilizes one side band component applied to Hilbert transform of one phase current to detect broken rotor bar faults under no-load condition. The principal component analysis and park vector based stator fault related feature is obtained. Memory cells are obtained for each healthy and faulty class in the training stage of artificial immune system. These memory cells are given to fuzzy-KNN to classify the test data set [22]. Choquet fuzzy fusion method integrates the performance of five methods and gives one decision result. An importance factor is determined for each method. The accuracy rate of diagnosis algorithm is increased by integration using choquet fuzzy integral.

rotor bar faults, a sample condition is given in TABLE III.


TABLE III. FEATURE INTEGRATION FOR BROKEN ROTOR BARS The feature Fuzzy degree Importance factors Entropy 1.00 0.2013 Skewness 1.00 0.2013 Kurtosis 1.00 0.2013 FBL 0.78 0.2013 FBU 0.96 0.1949 CFI 0.95

In TABLE III, fuzzy degree represents the membership value of a feature for broken rotor bar. The obtained fuzzy degrees of importance factors are normalized such that the sum of their values is one. To test the CFI, 80 healthy and faulty test samples are given to the algorithm. The output of CFI is demonstrated in Fig. 7.
1 0.8 0.6 0.4 0.2 0 0 20 40 60 Test sample 80

Fig. 7. The test results of CFI for broken rotor bar faults.

The first 40 samples show the healthy motor features. The maximum output of CFI is about 0.25.This means that the possibility of a broken rotor bar is 25%. Three features were used to test the framework on stator related faults. The test results are given in Fig. 8.
1 0.8 Output of CFI

0.37 kW Induction motor 0.37 kW Induction motor

Detection and diagnosis results

0.6 0.4 0.2 0 5 10 Test samples 15 20

Fig. 6. Experimental setup. TABLE II. INDUCTION MOTOR CHARACTERISTICS Description Value Power 0.37 kW Input Voltage 380 V Full Load Current 1.2 A Supply Frequency 50 Hz Number of Poles 4 Number of Rotor bars 22 Full Load Speed 1390 rpm

Fig. 8. The test results of CFI for stator faults.

The framework 1 is used to detect two faults, i.e. broken rotor bar and stator faults. Both the healthy and faulty features are given to the choquet fuzzy integral (CFI) and the severity of fault is estimated. For broken

To validate the framework 2, the importance factor was assigned to each diagnosis algorithm. This factor represents the capability of the algorithm. Each diagnosis algorithm gives an accuracy rate for given inputs. SVM gives better results than other algorithm. So, the importance factor is selected larger than other algorithms.

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TABLE IV shows the diagnosis results for each method and fusion of these methods combined by CFI.
TABLE IV. THE DIAGNOSIS RESULTS FOR EACH ALGORITHM AND FUZZY INTEGRAL The Method Accuracy rate (%) Importance factors NN 92.80 0. 050 SVM 98.95 0. 450 GC 95.35 0.150 AIS 96.33 0.175 FAIS 96.34 0.175 CFI 97.20

[8]

[9]

[10]

TABLE IV shows that CFI successfully integrates the results of different diagnosis algorithm and produce new one better result. This result is an integration of all algorithms. VI.
CONCLUSIONS

[11]

[12]

This paper has presented an intelligent fuzzy integral approach for fault diagnosis in induction motors. The method was implemented on two frameworks. The first framework integrates different features to improve the detection rate of broken rotor bar and stator faults. All features and their importance factor were determined using fuzzy membership functions. The negative effect of some features on detection performance was reduced. The second framework integrates five intelligent techniques on fault detection. Different features were extracted from current signals, and then used to evaluate the framework. Experimental results using broken rotor bar and stator faults showed that two frameworks preformed very well in recognizing faults. REFERENCES
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