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The aim of this paper is to present a Fault Detection and Isolation (FDI) system for
Permanent Magnet Synchronous Machines (PMSMs) based on vibration signals analysis.
First, a multi-physical model of the machine, able to generate vibration displacements under
different operating conditions, is simulated. The presented analytical modeling has been
compared and validated, in various papers, by a Finite Element Analysis (FEA).Then, time
and frequency domain signal processing techniques are applied to extract crucial features
sets, related to healthy and different faulty cases, from vibration displacements. In this study,
both rotor eccentricity and Permanent Magnet (PM) demagnetization faults are considered
and simulated in the analytical model. The asymmetry coefficient (skewness) and the median
frequency of the signal are selected as relevant fault-related indicators. Then, a pattern
recognition method based on a Multi-Layer Perceptron Artificial Neural Network (MLP
ANN) is used to detect the fault and to identify its type if existing. After all, an arbitrary set
of aforementioned indicators is used to test and validate the performance of the proposed
fault detection and diagnosis method.
1. Introduction
I ncandidates
the last decades, Permanent Magnet Synchronous Machines (PMSMs) have been good
for industrial applications like traction chains of electric vehicles due to their low
weight, high efficiency and higher torque density [1]. However, vibrations and acoustic noise are
generally considered as critical aspects for their on-board use [2]. Therefore, each fault, that may
increase vibration or noise level, must be detected and isolated at early stages to avoid its extensive
effects on the motor. Hence, a condition monitoring and detection system has become, over the past
40 years, a paramount task for industries to increase the availability and to reduce the maintenance
costs of rotating machines.
Recently, the analysis of machine signals acquired from different sensors, combined with the
Artificial Intelligence (AI), is one of the commonly used strategies for on-line fault diagnosis [3].
The type of these signals may be thermal, magnetic (magnetic field, flux density...), electrical
(motor currents, voltages...) or mechanical (torque, vibration…) [4]. However, as mentioned in [5],
electrical signals were insufficient to cover both electrical and mechanical health of the machine. As
well, the analysis of the flux density is not recommended for condition monitoring due to the search
coils sensors that must be installed in the air-gap during manufacturing [6]. Due to these limitations,
vibration signals have attracted the attention of many researchers to use them as effective
parameters for non-intrusive health monitoring of electrical machines [7] [8].
For this purpose, a vibration-based Fault Detection and Isolation (FDI) approach for PMSMs,
shown in fig 1, is developed and presented in this paper.
PMSM Faults
AI based Existing
Signal
PMSM Vibration Features on MLP
Processing Faults /
Modeling Signals Extraction Neural
Techniques severities
Network
2.1 EM model
The following EM model has been validated by Finite Element Analysis (FEA) in many papers
[10] [11] and a good agreement has been obtained. The radial component of the flux density ( )
in the air-gap is defined as the product of the air-gap permeance [12] and the total magnetomotive
force, created by the stator and the rotor, in both space ( ) and time (t) domains [2]. According to
) applied to the stator is calculated as given in Eq 1, where μ is the air magnetic permeability.
[8], the tangential component of the flux density can be neglected and the radial magnetic pressure
(
The calculated radial pressure is supposed to be the only source of vibration and acoustic noise in
the PMSM for vibration displacement calculation.
,
, =
2μ
(1)
compared to those issued from a Tow-Dimensional (2-D) FEA using ANSYS software and a good
agreement has been obtained [14].
The next step of the mechanical model is the calculation of the dynamic displacement signal of
mode (m) and the frequency (f) is calculated from the P θ , t one, based on Hooke's law [15].
the stator. The complex amplitude of the static displacement corresponding to the circumferential
Then, the complex amplitude of the dynamic displacement of the stator is obtained from the static
one by the mean of a complex magnification factor [12] as expressed in (2).
(2) , = , ×
, to obtain the
, in the ( , t) domain.
Finally, a 2-D Inverse Fast Fourier Transform (2-D IFFT) is applied to
displacement signal
A 24-slot four-pole PMSM, with parameters listed in Appendix A in [14], has been used as a ref-
erence motor. It is driven by a 3-phase current at constant frequency (50 Hz). Figure 2 gives the
space and time-domain dynamic displacement waveforms obtained under healthy conditions.
400 400
300 300
Displacement Signal (nm)
200 200
100
100
0
0
-100
-100
-200
-200
0 50 100 150 200 250 300 350 0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04
Angle (degrees) Time (sec)
(a) (b)
Figure 2: Analytical displacement signal in the space-domain (a) and in the time-domain (b)
For diagnosis purpose, some parameters of EM and mechanical models (MMF, air-gap perme-
ance, etc.) can be modified to simulate some faults and then, to study their effects on the displace-
ment signal as it will be detailed in the next section.
where Ω is the mechanical speed of the rotor, ' and ' are respectively the static and the dynamic
SE and DE faults with different degrees (' =0.02; 0.03; 0.04 and ' =0.02; 0.03; 0.04) have been
eccentricity degrees and is the initial space position.
simulated in the PMSM model. Figure 3(a) presents the time-domain displacement signal at an arbi-
trary space position under healthy, SE (' =0.04) and DE (' =0.03) cases.
0.3
0.2
0.1 (a)
-0.1
-0.2
Complete DMF
4
0 (b)
-2
-4
-6
Figure 3: Comparison between time-domain displacement signals under healthy, SE (40%) and DE
(30%) cases (a) and under healthy condition, partial (40%) and complete DMF (b)
1 5 1 5
(CF) (IF)
∑ − ∑
| :;1 1 ? 3 1−
5 B E
? 3 1 0C D
> @
0C D
1 5
1
− <=1 | ? 1 1 5 1 5 ∑ | |
∑ − ∑
? 3 1− ? 123 1
1 78# E/
123 ? 3 1
7 8 9
Average Power ( H) Mean frequency ( C ) Median frequency ( C )
O × GH J
KLMN KLMN KLPQ KLMN
I GH J I GH J = I GH J
H KLPQ
Table 3 shows the percentage of variation (in %) of different time and frequency indicators under
different conditions with some severities, with respect to the healthy case, calculated using equa-
tions of Table 1 and Table 2. As shown in this table, both indicators 5 (the skewness) and 9 (the
median frequency) can be used as relevant features to identify different operating conditions
(healthy, SE, DE, complete and partial DMF). Therefore, they are used as a vector of symptoms to
train and test the pattern recognition method for the FDI approach, as presented in the next section.
vibration signal are selected as inputs to the ANN and the 5 operating conditions with binary values
(0 or 1 for false or true respectively) are used as output patterns.
Table 3: The comparison of aforementioned indicators, with respect to the heathy case, under differ-
ent conditions
1 2 3 4 5 6 7 8 9
Healthy 0 0 0 0 0 0 0 0 0
SE (0.4) 7.49 2.75 -0.32 3.17 -64.58 3.89 5.57 1.38 0
DE (0.3) 12.41 0.91 4.21 10.05 38.27 10.62 1.83 0.15 0
The developed ANN and the number of training and test simulation signals, under each operating
condition, are shown in fig 4.
O1
Training signals Test signals
O2
O1=Healthy
I1 Healthy 20 1
O2=SE
I1=skewness O3 O3=DE SE 60 3
I2=median 10 hidden O4=complete DMF DE 60 3
frequency I2 neurons O5=Partial DMF
O4 Complete DMF 20 1
Partial DMF 60 3
O5
(a) (b)
The success rate of the proposed method is around 100% for each condition. The result demon-
strates that the combination of the selected features (skewness and median frequency) with the MLP
ANN-based recognition is effective in the detection and diagnosis of the considered faults (rotor
eccentricity and PM demagnetization)
5. Conclusion
The main goal of this paper was to develop a vibration-based Fault Detection and Isolation (FDI)
approach for PMSM. It was based on the combination of time and frequency features with the MLP
neural network. The skewness and the median frequency of analytical vibration signals were select-
ed as a set of signatures to represent the machine health. Then, a MLP ANN was developed to iden-
tify the operating condition of the PMSM and the type of the fault if existing. The accuracy of se-
lected indicators and the recognition method was also tested by a set of vibration signals for known
machine conditions, and a high success rate was obtained for all cases.
Moreover, other types of faults may occur in PMSMs and threat their performances such as the
Inter-turn Short-circuit Fault (ISF), bearing faults, etc. In the next step, these remaining faults will
be modelled and their effects on the vibration behaviour of the machine will be studied. In fact, the
application of conventional signal processing techniques (time and frequency domains) is only ef-
fective under stationary conditions. However, under non-stationary cases as run-up or run-down
processes, these techniques have some limitations which explain the need of mixed-domain signal
processing tools (time-frequency, wavelet, cyclostationarity tools …) for features extraction. In this
paper, the two input features were selected manually where the interest to apply, in future work, a
feature selection algorithm (chi2 for example) to improve the classification accuracy. As well, the
proposed FDI approach should be completed by a fault-characterization module that identifies the
severity of the existing fault. After all, a failure prognosis approach will be needed to predict the
future state of the PMSM during fault evolution.
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