Applied Soft Computing 1 (2001) 215223

Neural networks for load torque monitoring of an induction motor

Lucia Frosini , Giovanni Petrecca
Department of Electrical Engineering, University of Pavia, Via Ferrata 1, 27100 Pavia, Italy Received 11 December 2000; received in revised form 30 August 2001; accepted 19 October 2001

Abstract In this paper, the possibility to use neural networks for the monitoring of the load torque of induction motors is investigated. In particular, unsupervised neural networks are used to detect possible torque anomalies and supervised neural networks are used to identify the average value of steady-state load torque. These networks are trained and validated on the data gathered from a 1.5 kW three-phase squirrel-cage induction motor. Their generalisation abilities have been tested through the data collected with a 3 kW induction motor. 2001 Elsevier Science B.V. All rights reserved.
Keywords: Neural networks; Supervised and unsupervised learning algorithms; Multi-layer perceptron; Kohonen self-organised map; Induction motor; Load torque monitoring

1. Introduction In the eld of electrical machines, many problems of process control and diagnostic can be solved through identication and classication tools. Load torque monitoring of induction motors, for example, is useful for the detection of possible incipient faults and for having information about the working conditions of mechanical loads. The aim of this paper is to present the performance and the generalisation abilities of neural networks applied for load torque monitoring of induction motors. 2. Neural networks: supervised and unsupervised learning algorithms Neural networks can be classied according to their learning algorithms [9].
Corresponding author. E-mail address: lucia@unipv.it (L. Frosini).

The supervised learning algorithm adjusts the weights of inter-neuron connections according to the difference between the desired and actual network outputs corresponding to a given input. This point makes neural networks trained by supervised learning algorithm similar to black-box models: this kind of network is able to identify a system only through its input data and the corresponding output data, without knowing the physical insights of the system. The best known supervised neural network is the multi-layer perceptron (MLP). In general, MLP networks have an input layer, an output layer and one or more hidden layers. In Fig. 1, a MLP with a single hidden layer is reported. The unsupervised learning algorithm does not require, on the contrary, the knowledge of the desired outputs. During the training, only input patterns are presented to the neural network, which automatically adapts the weights of its interconnections in order to cluster the input patterns into groups with similar features. For this reason, neural networks trained by

1568-4946/01/$ see front matter 2001 Elsevier Science B.V. All rights reserved. PII: S 1 5 6 8 - 4 9 4 6 ( 0 1 ) 0 0 0 2 0 - 5

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Fig. 1. An MLP network with a single hidden layer, m inputs and n outputs.

used. The brake is regulated by a control and measurement system. The rst measurements have been made with a 1.5 kW three-phase squirrel-cage induction motor: the data collected have been used for the training and the validation of the neural networks. Second, the generalisation abilities of these neural networks have been tested through the data collected with a 3 kW induction motor. The rated torque of the rst motor is 10 N m, the rated torque of the second motor is 19.5 N m and the brake threshold is 2 N m. For most tests, the motors have been supplied directly from the mains. Only for particular tests, the motors have been supplied with inverter. The supply frequency is 50 Hz [2,6].

unsupervised learning algorithm can be effectively used for data classication. The best known unsupervised neural network is the Kohonen self-organised map (Fig. 2). The monitoring of the load torque of induction motors can be accomplished by neural networks: unsupervised neural networks can be used to detect possible torque anomalies and supervised neural networks can be used to identify the average value of steady-state load torque.

4. Classication of load anomalies through unsupervised neural networks Other authors have pointed out the possibility of classifying load anomalies of induction motors through neural networks [3,8]. In [3], the authors show that two types of load anomalies (oscillating load torque and periodic dip of torque) have particular effects on the machine supply current. Using the fast Fourier transform (FFT) of the stator current highlights these effects (current signatures). In the following, some considerations about the emergence of harmonic components in the current spectrum when a load failure occurs are reported. 4.1. Oscillating load torque An oscillating load torque is obtained by superimposing an oscillating torque of frequency fo to a constant torque (e.g. the rated torque Tr ). If the oscillation amplitude is small with respect to the constant torque, the problem can be treated in analytical way because the link between torque, speed and current values can be linearised. The expression of the load torque Tl is Tl = Tr + Tr cos(2fo t) (4.1)

3. Experimental set-up For the experimental phase a test bench equipped with an induction motor coupled with a brake has been

Fig. 2. A Kohonen self-organised map with m inputs and n outputs.

where is the oscillating torque referred to the rated one and t is the time.

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The relationship between the electromagnetic torque Te , the load torque Tl and the variation of the rotor speed r is J dr = Te Tl dt (4.2)

5. Classication of load anomalies: experimental phase In order to obtain a wide and representative set of measurements, the following 43 cases have been considered: 9 cases with constant load torque variable from 2 to 10 N m; 17 cases with oscillating load torque, obtained by superimposing an oscillating torque of frequency variable from 1.3 to 4.8 Hz and amplitude variable from 1 to 3 N m to a constant torque variable from 3 to 10 N m; 17 cases with periodic dip of torque, obtained by superimposing a square wave of frequency 2.5 Hz, duty ratio 20% and amplitude variable from 1 to 3 N m to a constant torque variable from 2 to 10 N m. For each case, four experimental tests and one simulation have been made. The simulation is realised through a model of the motor implemented with SIMULINK [5]. The 43 cases have been subdivided into the following two sets: 1. a training set composed of 25 cases (5 with constant torque, 10 with oscillating torque and 10 with periodic dip of torque); 2. a validation set composed of 18 cases (4 with constant torque, 7 with oscillating torque and 7 with periodic dip of torque). 5.1. Analysis of the harmonics components in the current spectrum In order to use the stator current for identifying the load anomalies, FFT has to be used. It has been observed that the variation of some parameters of FFT (representation scale and frequency resolution) strongly inuences the extraction of the current signatures [2,6]. 5.1.1. Representation scale: linear or logarithmic When linear representation scale is used, the current spectrum obtained from the experimental measurement is quite superimposed to the related spectrum obtained from the simulation (Fig. 3). This fact could be interesting in order to use a neural network trained

where J is the combined machineload inertia. As demonstrated in [3], when the load torque varies close to its rated value, the electromagnetic torque and the speed oscillate with the same frequency fo . Their amplitude and their displacement are dependent on the frequency itself, on the combined machineload inertia and on other machine parameters (pole pairs and rotor resistance). On the other hand, a speed variation introduces a current modulation at frequency fo [4]. Therefore, the instantaneous current value will show two spectral components at frequencies (f + f o ) and (f f o ), where f is the supply frequency: Is = Is0 cos(2 ft + 0 ) + Is1 cos(2(f + fo )t + 1 ) +Is2 cos(2(f fo )t + 2 ) (4.3) where 0 , 1 and 2 are the angular displacements referred to the torque pattern reference. The amplitude of the components Is1 and Is2 depends on the gain of the transfer function of the motor and supply system. This gain is a function of the motor and supply parameters and also depends on (f + f o ) and (f f o ) frequencies, and therefore, on load torque oscillation frequency fo . Moreover, for fo f the amplitudes of these two components are quite equal (see Figs. 5 and 6). 4.2. Periodic dip of torque A periodic dip of torque is obtained by superimposing a square wave of frequency fo to a constant torque. The duration of the dip is expressed by a percentage of the period of the square wave and is called duty ratio. In consequence of a periodic dip of torque, the current spectrum contains a sequence of harmonic components placed from the supply frequency at intervals multiple of fo . The duty ratio inuences the amplitude of the harmonic components located at distances which are multiple of frequency fa , where f a = f o /duty ratio (see Fig. 7).

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Fig. 3. Linear representations of simulated and experimental current spectra in a case of periodic dip of torque.

Fig. 5. Logarithmic representations of simulated and experimental current spectra in a case of oscillating torque.

through simulated data to detect the load anomalies of a real motor. But this representation does not permit to adequately highlight the harmonic components typical of these anomalies, so it is impossible to use this scale for the training set of a neural network (see Section 6.1). On the contrary, with logarithmic representation scale there are many differences between experimental and simulated current spectra (Fig. 4). The advantage offered by this representation scale is that harmonic components are highlighted (Fig. 5).

5.1.2. Frequency resolution: 1 or 0.5 Hz On the basis of the experience of other authors [3], a frequency resolution of 1 Hz has been chosen. This choice is good when the frequency fo of the oscillating torque or periodic dip of torque is larger than 1 Hz. When fo is close to 1 Hz or smaller, with this resolution the visibility of the harmonic components becomes worse. So, a frequency resolution of 0.5 Hz has been considered. The considerations about the opportunity

Fig. 4. Logarithmic representations of simulated and experimental current spectra in a case of constant torque.

Fig. 6. Comparison between 1 and 0.5 Hz frequency resolution in a case of oscillating torque with f o = 1.3 Hz.

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Fig. 7. Comparison between 1 and 0.5 Hz frequency resolution in a case of periodic dip of torque with f o = 2.5 Hz.

The neural network outputs are the neurons of the network, normally arranged as nodes of a squared grid; in our case, two different dimensions of the networks have been used: 400 neurons (20 20) and 625 neurons (25 25). The goal of the training phase is to obtain a subdivision of the map in three well-distinct areas corresponding to the considered three types of load torque (constant, oscillating, periodic dip). Once the training phase is ended, each vector of the training set activates one neuron of the network; the neurons activated by the vectors derived from the same type of load torque identify an area of the map specialised in the recognition of this type of load torque. Then, during the validation phase, a new set of data is presented to the network. If these vectors excite the neurons that belong to the desired area, the network is able to classify. In the following sections, the more signicant results obtained in this research are reported. 6.1. Frequency resolution of 1 Hz

to use this frequency resolution instead of a 1 Hz resolution are reported in the following sections (Figs. 6 and 7). 6. Classication of load anomalies: results In order to classify the load anomalies considered, unsupervised neural networks (Kohonen self-organised maps) have been trained. The neural network inputs are the vectors of the components of the current spectra. The choice of the number of components that are to be included in each vector must take into account the following considerations: 1. the more signicant components of the current spectra are near to the supply frequency; 2. an increasing in the number of components enlarges the dimension of the network; as a consequence, the training time is also increased. For these reasons, with a frequency resolution of 1 Hz, input vectors of 33 components have been used (from 34 to 66 Hz), while with a resolution of 0.5 Hz the input vectors were composed of 53 components, from 37 to 63 Hz.

It has been proven that a linear scale does not permit to train a network able to recognise the type of load torque. So, in the following tests only logarithmic scale has been used. It has been proven that networks trained with simulation data are not able to correctly classify the experimental data: almost all the experimental data are classied as periodic dip of torque. A network of 400 neurons trained with the data relating to an experimental test is able to correctly classify 15 cases over 18 during the validation phase. A network of 400 neurons trained with the averaged data relating to four experimental tests has correctly classied 17 cases on 18 during the validation phase. A network of 625 neurons trained with the same data of the previous network has correctly classied all the 18 validation data. In the following this network is called A. 6.2. Frequency resolution of 0.5 Hz A network of 625 neurons trained with the averaged data relating to four experimental tests has correctly classied 17 cases over 18 during the validation phase. In the following this network is called B.

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Consequently, a frequency resolution of 0.5 Hz does not appear suitable in comparison to a frequency resolution of 1 Hz, because it increases the required memory and the training time without improving the performance of the network. 6.3. Test on generalisation ability of the networks As induction motors are often supplied through inverter, we have veried whether the neural networks trained with the current spectra of the motor directly supplied are able to classify the torque anomalies revealed by the current spectra of the same motor supplied by inverter. In fact, when the motor is supplied through inverter, the supply voltage contains some harmonic components. Consequently, the current spectrum contains further harmonic components, and therefore, it is more difcult to extract the signature of the load anomalies. For each of the 43 cases considered (see Section 5) four new experimental tests have been made with the motor supplied through its inverter. The current spectra have been averaged on the four experimental tests. It has been proven that the network A (resolution frequency of 1 Hz) is able to correctly classify 42 cases on 43. The network B (resolution frequency of 0.5 Hz) is able to correctly classify 39 cases on 43. In order to check the generalisation ability of neural networks, four experimental tests related to 18 new cases have been made on a 3 kW motor: six cases with constant torque; six cases with oscillating torque; six cases with periodic dip of torque. The network A has correctly classied all the cases using the averaged data on the four experimental tests. The network B has correctly classied 17 cases over 18. The conclusion is that neural networks trained with the data gathered from the rst motor display good generalisation ability when tested on a different size motor. 7. Identication of electromagnetic torque through supervised neural networks Supervised neural networks, such as MLP, can be employed as parametric black-box models in system

identication, in order to obtain better performance than classic models (e.g. polynomial). Normally, a neural network has a better performance than a polynomial model when the system to be identied is non-linear. Moreover, the generalisation ability of neural networks is normally better than polynomial models. For these reasons, in [7] MLP networks and polynomial models have been used for the identication of the electromagnetic torque (Te ) in induction motors as an alternative to the physical model provided by the equivalent circuit theory. In fact, the physical model of Te requires the knowledge of some variables usually not available in normal operating conditions, such as the equivalent circuit parameters (rotor resistance Rr , rotor leakage inductance Lr , magnetising inductance Lm ): Te = 3pRr (2f pr )
2I 2 Lm s Rr 2 /(2f pr )2 + (Lr + Lm )2

(7.1)

According to the above expression the torque is calculated through the values of the phase stator current Is , rotor speed r , supply frequency f, number of pole pairs p and equivalent circuit parameters. Whereas we can easily measure the rst three variables, it is very difcult to know the exact values of the equivalent circuit parameters. Sometimes the manufacturers can provide these values, but often it is necessary to calculate them through special tests; in this way, we can obtain only approximate values for the equivalent circuit parameters, and thus, an approximate value for Te . Because of the dependence of Te from the stator current Is and the rotor speed m , we can use a black-box identication approach to determine the dependence of Te upon these variables. The black-box identication through neural models consists of determining the parameter vector of the weights of the network from a set of observed data (called training set) including a set of input values x1 (t), x2 (t), . . . , xn (t) and the corresponding output values y(t): Z N = [x1 (t), x2 (t), . . . , xn (t), y(t)], t = 1, . . . , N (7.2)

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The goal of the training phase is to determine a map from the set of training data to the set ping Z N of possible parameters so that the model will produce outputs y(t | ) which in some sense are close to the true values y(t) [10]. To solve this problem, a measure of closeness in terms of mean of squared residuals (MSR) is introduced: MSR(, Z N ) = 1 N
N t =1

This has been repeated with a load changing from 2 N m (the brake threshold) up to the rated electromagnetic torque, 10 N m. We note that, according to (4.2), electromagnetic torque Te is equal to load torque Tl when the rotor speed r is constant. The 26 observed groups of data have been subdivided into two sets of 13 vectors that have been used for identication and validation, respectively. 9. Identication of electromagnetic torque: results In order to identify the model of Te MLP networks with a single hidden layer have been used. For the estimate of the parameters of the networks we employed the LevenbergMarquardt algorithm, due to its rapid convergence property and robustness, and the performance function (7.6). For the choice of the number of the hidden neurons a trial and error method has been used: starting from the simplest model (one neuron with linear function) and increasing the complexity of the network (one hyperbolic neuron, two linear neurons, two hyperbolic neurons, etc.). The method stops when the performance function of the network calculated on the validation data becomes worse. So, the following parameters have been modied from time to time: number of hidden neurons and their activation function (linear or hyperbolic); value of parameter in (7.6), that can be varied from 0 to 1: when the value of is near to 1, the weight of the regularisation term is lower. The best neural network model has three hyperbolic neurons and = 0.9. Its MSR calculated on the validation data is: MSRV = 0.0125. This performance is slightly better than the best polynomial model performance (MSRV = 0.0126) [7]. In the opinion of the authors, the mere slight improvement obtained by neural models depends on the quite regular dependence of the electromagnetic torque on the rms value of the stator current and on the rotor speed. So, for the collected data, this dependence can be explained with sufcient precision through a classical polynomial model. The performance of MLP network dened as average absolute error (AAE) in percentage on all

(y(t) y(t | ))T (7.3)

(y(t) y(t | ))

If et is the generic residual (difference from the actual value y(t) and the corresponding output of the model y(t | )), Eq. (7.3) can be written as follows: MSR(, Z N ) = 1 N
N

(et )2
t =1

(7.4)

The parameters are then found as = arg min MSR(, Z N )

(7.5)

Eq. (7.5) is solvable in closed form when the dependence of y(t | ) from is linear (e.g. polynomial model) or by iterative algorithm when this dependence is non-linear (e.g. MLP network). Finally, the derived model has to be validated on a fresh set of data, called validation set. In order to improve the generalisation ability of neural networks a regularisation term is added to the MSR, so that the performance function becomes [1]: MSR(, Z N ) = 1 N
N

(et )2 + (1 )
t =1

1 n

(wj )2
j =1

(7.6) where is a constant, n the number of weights of the neural network and wj is the generic weight of the network.

8. Identication of electromagnetic torque: experimental phase The experimental test is based on the measurements of the following values: average electromagnetic torque Te , rms value of the stator current Is , average rotor speed r .

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Fig. 8. Comparison of the calculated values through the three models and the collected values of torque (polynomial model is almost superimposed on neural model).

the data has been compared to equivalent circuit theory: neural model: AAE = 1.88%; equivalent circuit theory: AAE = 36.82%. The value of the AAE produced by the equivalent circuit theory may be partly explained by the friction

and windage losses, that are strictly dependent from the rotor speed and become more relevant in low load conditions. These losses are included in the expression of the electromagnetic torque (7.1), while they have to be subtracted to this expression in order to obtain the value of the torque available at the load shaft (see Fig. 8).

Fig. 9. Comparison of the outputs of the polynomial and neural models and the collected values of torque (3 kW motor)

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The generalisation ability of the neural network has been tested using nine groups of data collected from a 3 kW induction motor. The performance is calculated as AAE in percentage on these data: AAE = 21.90%. The conclusion is that it is possible to know an approximate average torque value of a motor by using a model identied and validated on another motor, without knowing the equivalent circuit parameters. This approximation is, therefore, better than the approximation obtained by the equivalent circuit theory. On the contrary, the generalisation ability of the polynomial model is unacceptable: AAE = 93.40% (see Fig. 9).

10. Conclusions In this paper, the possibility to employ neural networks as a useful tool for the classication of load anomalies and the identication of load torque of induction motors has been investigated. The earlier sections (particularly Sections 46) point out the results of unsupervised neural networks applied to classify two types of load anomalies (oscillating load torque and periodic dip of torque). The neural network inputs are the harmonic components of the spectrum of one-phase stator current. Several networks are tested using a different scale to represent the FFT of the current (linear or logarithmic), a different frequency resolution (0.5 or 1 Hz), and increasing dimension of the network. The results show that a network trained on data collected from a 1.5 kW motor directly supplied is able to recognise the same load anomalies revealed by the same motor supplied through an inverter. Moreover, a network trained on data collected from 1.5 kW motor is able to recognise similar load anomalies coming from a 3 kW motor. The last sections of this paper (from Section 7 to 9) present the results of black-box identication of steady-state electromagnetic torque (Te ). The physical model of Te provided by the equivalent circuit theory requires the knowledge of some variables usually not available in normal operating conditions (the equivalent circuit parameters). Because of the dependence of Te on the stator current Is and the rotor speed r , a black-box identication approach can be used to determine the dependence of Te upon these variables.

In this research, polynomial and neural models have been employed; the latter are based on MLP networks trained by LevenbergMarquardt algorithm (a supervised algorithm). Both polynomial and neural models are identied and validated on the data collected from a 1.5 kW motor, obtaining an AAE lower than 2%. The generalisation ability is checked testing these models on a different size of motor (3 kW); the results show poor generalisation ability in the polynomial case but pretty good generalisation ability in the neural case: the approximation is better than the approximation obtained by the equivalent circuit theory. Future work will consider the acquisition of data relating to other motors in order to develop an instrument for the monitoring of the load torque of induction motors in a certain range of power. References
[1] H. Demuth, M. Beale, Neural Network Toolbox for Use with MATLAB , The MathWorks Inc., 1998. [2] M. Fanoli, Reti neurali articiali ad apprendimento non-supervisionato per la diagnostica dei motori asincroni (Unsupervised neural networks for diagnostics of induction motors), M.Sc. Thesis in Electrical Engineering, University of Pavia, Italy, July 1999 (in Italian). [3] F. Filippetti, G. Salles, G. Grellet, C. Tassoni, G. Franceschini, Monitoring of an actuators load by neural network, in: Proceedings of the SDEMPED97, pp. 296301. [4] F. Filippetti, G. Franceschini, C. Tassoni, Neural networks aided on-line diagnostics of induction motor rotor faults, IEEE Trans. Ind. Appl. 31 (4) (1995) 892899. [5] L. Franchi, Sorveglianza della coppia di un motore asincrono con reti neurali (Torque monitoring of induction motor with neural networks), M.Sc. Thesis in Electrical Engineering, University of Pavia, Italy, January 1999 (in Italian). [6] L. Frosini, Impiego delle reti neurali per applicazioni nel campo della conversione dellenergia (Applications of neural networks in the energy conversion eld), Ph.D. Thesis in Electrical Engineering, University of Pavia, Italy, October 1999 (in Italian). [7] L. Frosini, G. Petrecca, Black-box identication of the electromagnetic torque of induction motors: polynomial and neural models, in: Proceedings of the IEA/AIE-2000, New Orleans, USA, June 2000, pp. 741748. [8] J. Penman, C.M. Yin, Feasibility of using unsupervised learning, articial neural networks for the condition monitoring of electrical machines, IEEE Proc. Electr. Power Appl. 141 (6) (1994) 317322. [9] D.T. Pham, X. Liu, Neural Networks for Identication, Prediction and Control, Springer, Berlin, 1995. [10] J. Sjberg, H. Hjalmerson, L. Ljung, Neural Networks in System Identication, in: Proceedings of the 10th IFAC Symposium on SYSID, Copenhagen, Denmark, 1994.