A Data-Driven Approach To Monitoring Wind Turbine Faults

A Data-driven Approach to Monitoring Wind
Turbine Faults
Graduate Student: Zijun Zhang and Anoop Verma
PI: Prof. Andrew Kusiak
Intelligent Systems Laboratory
The University of Iowa
September 21st, 2011
Outline
Gearbox fault identification
1. Analysis of Case 2a
2. Analysis of Case 2b
3. Analysis of Case 2c
Monitoring gearbox fault

1. Data-driven jerk prediction model
2. Monitoring models
Discussion
Gearbox Fault Identification

Jerk the rate of acceleration change, and it is often used
to indicate the excitement of vibration.
at at T
J
T

da
at at T
a at at T

= lim
=
J=
, a = at at T and t = t (t T )
0
t t (t T )
dt
T
Data processing Convert 40kHz data to 1/15kHz. In the

data conversion, estimate max, min and standard deviation.

Analysis of Case 2a
Time domain analysis
Maximum of change of generator speed

Pattern of maximal Jerk for AN4
600
500
25
400
20
300
Maximal of jerk
Maximal rate of speed (rpm/15-s)
200
100
0
1
9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Time (15 s interva ls)
Speed of encoder on HSS
15
10
5
0
1
9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Time (15 s intervals)

Analysis of Case 2a
Frequency domain analysis Fourier transformation with time window
0.035
0.04
0.025
0.035
0.02
0.03
0.025
0.015
Power
Power
0.03
5th minute
0.01
0.02
0.015
0.005
0.01
500
1000
1500
2000
2500
Frequency (Hz)
2nd minute
3000
3500
4000
0.005
0
500
1000
1500
2000
2500
Frequency (Hz)
3000
3500
4000

Analysis of Case 2b
Comparison between 2a and 2b
Sensors
AN1
AN2
AN3
AN4
AN5
AN6
AN7
AN8
AN9
AN10
AN11
AN12
Mean of maximum jerk of 2b
0.6
0.6
4.4
5.0
7.2
13.0
9.6
17.4
18.9
6.1
9.9
23.4
Mean of maximum jerk of 2a
0.7
0.8
9.4
14.2
3.1
5.8
4.6
8.3
8.4
5.3
6.7
10.4
Correlation Coefficient Analysis
Clustering Analysis
Sensors
AN1
AN2
AN3
AN4
AN5
AN6
AN7
AN8
AN9
AN10
AN11
AN12
Sensors
Index of clusters
AN1
1.00
0.98
0.53
0.20
0.02
0.14
0.00
-0.11
0.16
0.16
0.16
0.03
AN1
AN2
0.98
1.00
0.59
0.06
0.18
0.30
0.17
0.05
0.32
0.25
0.33
0.19
AN2
AN3
0.53
0.59
1.00
0.09
0.31
0.53
0.41
0.19
0.62
0.77
0.48
0.32
AN3
AN4
0.20
0.06
0.09
1.00
-0.88
-0.78
-0.85
-0.94
-0.70
-0.11
-0.76
-0.89
AN4
AN5
0.02
0.18
0.31
-0.88
1.00
0.94
0.97
0.97
0.90
0.50
0.92
0.97
AN5
AN6
0.14
0.30
0.53
-0.78
0.94
1.00
0.98
0.93
0.99
0.60
0.95
0.96
AN6
AN7
0.00
0.17
0.41
-0.85
0.97
0.98
1.00
0.97
0.96
0.56
0.94
0.97
AN7
AN8
-0.11
0.05
0.19
-0.94
0.97
0.93
0.97
1.00
0.88
0.39
0.90
0.98
AN8
AN9
0.16
0.32
0.62
-0.70
0.90
0.99
0.96
0.88
1.00
0.67
0.92
0.93
AN9
AN10
0.16
0.25
0.77
-0.11
0.50
0.60
0.56
0.39
0.67
1.00
0.59
0.42
AN10
AN11
0.16
0.33
0.48
-0.76
0.92
0.95
0.94
0.90
0.92
0.59
1.00
0.92
AN11
AN12
0.03
0.19
0.32
-0.89
0.97
0.96
0.97
0.98
0.93
0.42
0.92
1.00
AN12

Analysis of Case 2b
Cluster 1
0.00
2.31
3.41
Cluster 3
3.41
5.72
0.00
1.24
1.64
1.62
1.6
1.58
1.56
1.54
1.52
1.5
1.48
1.46
1.44
1.42
Standard devuiation of jerk
Mean of jerk
Cluster 1
Cluster 2
Cluster 3
Cluster 2
2.31
0.00
5.72
1.22
1.2
1.18
1.16
1.14
1.12
1.1
1.08
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
AN7
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
AN7

Frequency domain analysis
0.16
0.12
0.14
0.1
0.12
0.1
Power
Power
0.08
0.06
0.08
0.06
0.04
0.04
0.02
0.02
500
1000
1500
2000
2500
Frequency (Hz)
3000
3500
4000
500
1000
2500
2000
1500
Frequency (Hz)
3000
3500
4000

Analysis of Case 2c
Comparison between 2a, 2b and 2c

Sensor
AN1
AN2
AN3
AN4
AN5
AN6
AN7
AN8
AN9
AN10
AN11
AN12
Mean of maximum jerk in 2b
0.6
0.6
4.4
5.0
7.2
13.0
9.6
17.4
18.9
6.1
9.9
23.4
Mean of maximum jerk in 2a
0.7
0.8
9.4
14.2
3.1
5.8
4.6
8.3
8.4
5.3
6.7
10.4
Mean of maximum jerk in 2c
3.22
5.11
6.09
8.73
8.53
15.18
12.80
20.71
22.57
7.50
10.53
28.33
Correlation Coefficient Analysis
Clustering Analysis
Sensor
AN1
AN2
AN3
AN4
AN5
AN6
AN7
AN8
AN9
AN10
AN11
AN12
AN1
1.00
0.83
0.32
-0.73
0.50
0.56
0.49
0.67
0.49
0.48
0.64
0.56
AN1
AN2
0.83
1.00
0.76
-0.91
0.88
0.90
0.87
0.92
0.87
0.86
0.91
0.91
AN2
AN3
0.32
0.76
1.00
-0.67
0.94
0.92
0.95
0.78
0.96
0.95
0.80
0.90
AN3
AN4
-0.73
-0.91
-0.67
1.00
-0.85
-0.90
-0.84
-0.97
-0.83
-0.80
-0.94
-0.91
AN4
AN5
0.50
0.88
0.94
-0.85
1.00
0.99
0.99
0.92
0.99
0.98
0.92
0.98
AN5
AN6
0.56
0.90
0.92
-0.90
0.99
1.00
0.99
0.95
0.98
0.97
0.95
0.99
AN6
AN7
0.49
0.87
0.95
-0.84
0.99
0.99
1.00
0.91
0.99
0.98
0.92
0.98
AN7
AN8
0.67
0.92
0.78
-0.97
0.92
0.95
0.91
1.00
0.91
0.88
0.96
0.96
AN8
AN9
0.49
0.87
0.96
-0.83
0.99
0.98
0.99
0.91
1.00
0.98
0.90
0.98
AN9
AN10
0.48
0.86
0.95
-0.80
0.98
0.97
0.98
0.88
0.98
1.00
0.88
0.96
AN10
AN11
0.64
0.91
0.80
-0.94
0.92
0.95
0.92
0.96
0.90
0.88
1.00
0.96
AN11
AN12
0.56
0.91
0.90
-0.91
0.98
0.99
0.98
0.96
0.98
0.96
0.96
1.00
AN12
Sensors
Index of clusters

Analysis of Case 2c
Cluster 1
Cluster 2
Cluster 3
Cluster 1
0.00
2.26
3.26
Cluster 2
2.26
0.00
5.52
1.65
2.2
Standard deviation of jerk
2.15
2.1
Mean of jerk
Cluster 3
3.26
5.52
0.00
2.05
2
1.95
1.9
1.85
1.8
1.6
1.55
1.5
1.45
1.4
1.35
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
AN7
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
AN7
Monitoring Gearbox Fault

Data driven single-signal jerk prediction model
J AN7,t = f ( J AN7,t T , J AN7,t 2T , J AN7,t 3T , J AN7,t 9T , J AN7,t 10T )
Parameter description
Parameter
JAN7,t T
JAN7,t 2T
JAN7,t 3T
JAN7,t 9T
JAN7,t 10T
Importance
100
96
93
93
92
Parameter
JAN7,t 8T
JAN7,t 4T
JAN7,t 5T
JAN7,t 7T
JAN7,t 6T
Importance
92
90
90
89
82

Test results
Algorithm
NN
NNE
BT
RF
CART
SVM
KNN
MAE
0.0445
0.0446
0.0427
0.0505
0.0573
0.0408
0.0505
SDofAE
0.0329
0.0331
0.0315
0.0361
0.0391
0.0296
0.0388
MAPE
0.0207
0.0208
0.0200
0.0235
0.0266
0.0192
0.0235
SDofAPE
0.0150
0.0151
0.0144
0.0163
0.0176
0.0138
0.0178
2.25
First 100 test points
Jerk (m/s3)
2.2
2.15
2.1
2.05
2
1.95
1
5
9
13
17
21
25
29
33
37
41
45
49
53
57
61
65
69
73
77
81
85
89
93
97
1.9
Time (0.1-s interva ls)
Observed va lue
Predicted va lue

Modified x-bar chart
m
=
t [ ( yi yi )] / m
i =1
=
st
[ (( y i yi ) t ) 2 ] /(m 1)
i =1
UCL=
t + c( st / q )
x
CL x = t
=
LCL x max{0, t c( st / q )}
The UCLx, CLx and LCLx represent the upper control limit, centerline, and lower control limit
of the modified x-bar chart, respectively. The parameter c controls the width between the upper
and lower control limit. The parameter q denotes the number of sampling data points. The
parameter t represents the mean of the test dataset, st describes the standard deviation of the
test dataset and m is the total number of data points in the test dataset

Modified x-bar chart
Test of process shift

0.14
0.07
0.12
Absolute percenta ge error
0.08
0.06
0.05
0.04
0.03
0.02
0.01
0.1
0.08
0.06
0.04
0.02
1
21
41
61
81
101
121
141
161
181
201
221
241
261
281
301
321
341
361
381
401
421
441
461
481
0
1
21
41
61
81
101
121
141
161
181
201
221
241
261
281
301
321
341
361
381
401
421
441
461
481
Absolute percenta ge error
Training control chart
Time (0.1s intervals)
Time (0.1s intervals)

Residuals
Centerline
Upper bound
Lower bound
Residuals
Centerline
Upper bound
Lower bound

EWMA (Exponentially Weighted Moving Average) chart
zi = xi + (1 ) zi 1
UCL EWMA = t + Lst
[1 (1 ) 2i ]
2
CL EWMA = t
LCL
max{0, t Lst
=
EWMA
[1 (1 ) 2i ]}
2
Parameter z presents the EWMA, x is the prediction residual and i is the index of a
data point. L and are two parameters that need to be arbitrarily set to develop the
EWMA chart.

Results of EWMA chart
Absolute percentage error
0.06
0.05
0.04
0.03
0.02
0.01
0
1
11 13 15 17 19 21 23 25 27 29
Time (0.1-s intervals)
EWMA
Centerline
Upper bound
Lower bound
Discussion
Data collected from the nacelle fixed on the
floor. The data might not fully reflect the
vibration of the gearbox in the real wind
turbine.
In the industry, wind turbines usually
contain only two accelerometers, some
might have six accelerometers.
Sensors
Accelerometer No. 1
Accelerometer No. 2
Accelerometer No. 3
Accelerometer No. 4
Accelerometer No. 5
Symbols
AN1
AN2
AN3
AN4
AN5
Accelerometer No. 6
AN6
Accelerometer No. 7
AN7
Accelerometer No. 8
AN8
Accelerometer No. 9
AN9
Accelerometer No. 10
AN10
AN11
AN12
Generator speed
Low speed shaft torque
Locations
Main bearing radial
Main bearing axial
Ring gear radial 6 oclock
Ring gear radial 12 oclock
Low speed shaft radial
Intermediate speed shaft
radial
High speed shaft radial
High speed shaft upwind
bearing radial
High speed shaft
downwind bearing radial
Carrier downwind radial
Generator upwind radial
Generator downwind axial
Encoder on high speed
shaft
Strain gauges on low speed
shaft
Plus acceleration directions

+Z and -Y
-X
-Z
+Z
+Y and -Z
Units
m/s2
m/s2
m/s2
m/s2
m/s2
+Y and -Z
m/s2
+Y and +Z
m/s2
+Z
m/s2
+Z
m/s2
+Y
+Z and -Y
+Z and -Y
m/s2
m/s2
m/s2
Null
rpm
Null
kNm

A Data-Driven Approach To Monitoring Wind Turbine Faults

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A Data-driven Approach to Monitoring Wind

Intelligent Systems Laboratory

Monitoring gearbox fault

Intelligent Systems Laboratory

Gearbox Fault Identification

Data processing Convert 40kHz data to 1/15kHz. In the

The University of Iowa

Intelligent Systems Laboratory

Gearbox Fault Identification

Maximum of change of generator speed

Maximal rate of speed (rpm/15-s)

The University of Iowa

Intelligent Systems Laboratory

Gearbox Fault Identification

The University of Iowa

Intelligent Systems Laboratory

Gearbox Fault Identification

Mean of maximum jerk of 2b

Mean of maximum jerk of 2a

Correlation Coefficient Analysis

The University of Iowa

Intelligent Systems Laboratory

Gearbox Fault Identification

Standard devuiation of jerk

The University of Iowa

Intelligent Systems Laboratory

Gearbox Fault Identification

The University of Iowa

Intelligent Systems Laboratory

Gearbox Fault Identification

Comparison between 2a, 2b and 2c

Mean of maximum jerk in 2b

Mean of maximum jerk in 2a

Mean of maximum jerk in 2c

Correlation Coefficient Analysis

The University of Iowa

Intelligent Systems Laboratory

Gearbox Fault Identification

Standard deviation of jerk

The University of Iowa

Intelligent Systems Laboratory

Monitoring Gearbox Fault

The University of Iowa

Intelligent Systems Laboratory

Monitoring Gearbox Fault

First 100 test points

The University of Iowa

Intelligent Systems Laboratory

Monitoring Gearbox Fault

The University of Iowa

Intelligent Systems Laboratory

Monitoring Gearbox Fault

Test of process shift

Absolute percenta ge error

Absolute percenta ge error

Training control chart

Time (0.1s intervals)

Time (0.1s intervals)

The University of Iowa

Intelligent Systems Laboratory

Monitoring Gearbox Fault

The University of Iowa