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Machinery Fault Identification Using Blind Sound Separation and Fuzzy

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Conference Paper · January 2011

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 Machinery Fault Identification Using Blind Sound Separation and Fuzzy System

*Bagus T. Atmaja, Dhany Arifianto

Department of Engineering Physics
Sepuluh Nopember Institute of Technology
Sukolilo Campus, Surabaya 60111, Indonesia
btatmaja@gmail.com, dhany@ep.its.ac.id

Abstract: Early and accurate fault detection on the machine is crucial in a preventive maintenance in order to
prevent accidents that may be catastrophe to the production sustainability as well as the company. In this paper, we
propose a novel technique for remote condition monitoring by analyzing sound emitted from the machines. We used
normal, unbalanced, bearing fault machines worked simultaneously recorded in anechoic chamber to simulate the real
plant situation. We assumed that the sounds mixed convolutively at which required microphone array as sensor as
an interface before separation. Using time-, frequency-domain, and combined techniques the sound mixtures were
successfully separated. Fuzzy inference system was then applied to classify the fault type based on the frequency
estimates. The results suggest that the proposed technique performed accurately in mean-square-error (MSE) sense.
This implies that the proposed technique may be suitable for further implementation in real plant setting to replace
current technique using direct measurement.

1 I NTRODUCTION data (output of the sensors), called independence, ICA can

Machine condition monitoring plays an important role in
production sustainability in an industry using rotating ma-
chineries such as pump, compressor, etc. Essentially, this type
of machinery is driven by electrical input and transformed into
mechanical energy (rotation). The rotation and its interac-
tion between moving parts during cyclic motion cause vibra-
tion and emit audible sound. Due to mechanical imperfection
such as wear-time, friction, the each rotating machinery has a
unique sound characteristic. This research focuses on analyz-
ing the emitted vibration sound of its particular frequency, in
which, the damage of one particular part of the rotating ma-
chine will emit a specific frequency [1].
The direct measurement, the common practice, must be
conducted on each machine plant-wide using hand-held vi-
brometer. This naturally takes a considerable effort and time.
Condition monitoring based on frequency analysis of the ma-
chine sound emission received a considerable attention re-
cently [2]. Compared to the common technique, the frequency
technique offers more flexibility because of non-contact mea-
surement. The accurate measurement of sound signal of ma-
chine reflects the real condition of machine and will give the
same outcome as the vibration analysis technique. Further-
more, it opens many new possibilities for remote and simulta-
neous online and real-time condition monitoring.
However, most of the plant uses more than one rotating
machineries placed in a cluster. It is difficult and not eco-
nomical to use one dedicated sensor to each machine. In this
research we proposed a novel technique to address this prob-
lem by using independent component analysis technique to
separate the sound mixtures of the machines acquired by mi-
crophone array [3]. After separation, the individual signal is
analyzed to extract the frequency content using the instanta-
neous frequency analysis [4, 5] and then using fuzzy inference
engine it automatically displays the condition of the machine
whether it is normal or not.
Independent component analysis (ICA) is a blind source
separation technique to separate a mixture of signal acquired
by sensor without any knowledge on how the mixing pro-
cess takes place [6]. Based on statistical properties of the
identify and rearrange the mixture into its respective origi-
nal emission source. To best of our knowledge, the time-,
frequency-domain, and combined technique (multistage) ICA
were applied to separate simultaneous speech [7], and here
we applied them with minor modification into rotating ma-
chinery sound emission. We argue that a normal rotating ma-
chine emits sound that similar to white noise, i.e. no harmonic
structure while for faulty machine, the harmonics are observ-
able. In the experiment we used commercial water-pump with
normal, unbalanced, mechanical looseness and bearing fault
to simulate the common problem arises in rotating machine.
First, we recorded one condition with one sensor in an ane-
choic chamber used as baseline to measure the separation al-
gorithm performance. The fuzzy inference engine contained
with reference frequencies of normal and abnormal operation
and was developed based on experience and compared to the
best practice in gas industry. Since there is no clear-cut bound-
ary between frequency of one condition to another, we chose
Tsukamoto fuzzy to obtain smooth transition between condi-
tion [8]. The proposed technique performed satisfactorily to
separate the sound mixture in mean-square-error sense.
The organization of the paper is as follows. The next sec-
tion will discuss about the rotating machine and then followed
by ICA at a glance. The experimental procedures will be ex-
plained in detail with discussion of the results. We will then
present some concluding remarks and the on-going research.
2 M ACHINE C ONDITION T YPES
The rotating machine is a class of machinery whose some
parts move periodically over time and causes vibration [9].
This vibration in many cases is audible due to the size and the
power. In our experiment, we used an electrical motor to re-
placed big machine whose configuration is shown in Fig. 1.
Figure 1 shows parts of typical the rotating machine which
consists of motor, stator, bearing, shaft, impeller/blade, etc.
Besides normal condition, machine fault is typically caused
by a failure of one or more components. However for the sim-
plicity of the experiment without losing the generality we only
introduced one specific failure to one machine. The machine
 the mixing process. In causal finite impulse response (FIR)
filter, we cast the separation process into,
L
X
y(t) = W(l)s(t − l), (3)
l=0

where y(t) = [y1 (t), . . . , ym (t)]T are the independent esti-

mate of each source s(t). Consequently, from eq. 1 we can
estimate y(t). We used Kullback-Leibler divergence measure
for criterion of variable independency as suggested in [11].
P2
I(Y1 , Y2 ) = i=1 H(Yi ) − H(Y1 , Y2 ), I is mutual informa-
tion and H is the entropy of respective information Y1 and Y2 .
Fig. 1: Diagram of Rotating Machine and Its Parts [10] Therefore, we minimized
Z
p(Y1 , Y2 )
I(Y1 , Y2 ) = p(Y1 , Y2 ) log dY1 dY2 (4)
condition used in the experiment related to its vibration can p(Y1 )p(Y2 )
be described as follows:
In our experiment, we used natural gradient algorithm to
• Normal, this a the condition of normal machine without find the best of W outlined in [12]. The W in natural gradient
any faults. algorithm is defined as follow,
• Unbalance, this is the most common failure because of ∂J(Wk ) T
uneven or unbalance mass at the rotor or rotating part as Wk+1 = Wk − µ Wk Wk (5)
∂W
the centre of rotation.
• Misalignment, this condition was occurred due to asym- The µ in equation above reflected block step used in separa-
metry of shaft when aligning two or more machines shaft tion process and J is the Jacobian matrix of W. This separat-
to be coupled to be an integrated machine. ing filter will make estimated signal y. The time-domain ICA
• Bearing Fault, it can be caused by failure of ball bearing, model is written as follows,
inner race, outer race, ball cage or bearing house. L
X
y(t) = W(τ )X(t − τ ), (6)
It is common knowledge that the same machine will emit
τ =0
different sound with respect to the type of its failure because
of the change in the fundamental frequency of the sound emit- where y(t) = [y1 (t), . . . , yn (t)]T is the output and W(τ ) is
ted. The normal sound is similar to white noise in which the the τ -tap of the separating filter.
harmonic on the sound wave does not exist. The more num-
ber of harmonics presents the more severe the damage on the X(ω, t) = H(ω)S(ω, t). (7)
machine.
The equation 7 is for frequency domain ICA (FDICA). Eq. 2
in frequency domain becomes the following separating ma-
3 B LIND S OUND S EPARATION trix,
Let s(t) be time domain source signal, S(f ) be its Fourier
X1 (ω, t) W11 (ω) W21 (ω) W13 (ω) Y1 (ω, t)
" # " #" #
transform and its bold case is its matrix form, respectively. In
convolutive mixture problem, let m be statistically mutually X2 (ω, t) = W21 (ω) W22 (ω) W23 (ω) Y2 (ω, t)
independent sources s(t) = [s1 (t), . . . , sm (t)]T and n mix- X3 (ω, t) W31 (ω) W32 (ω) W33 (ω) Y3 (ω, t)
ture observations x(t) = [x1 (t), . . . , xn (t)]T are given by (8)
For optimal W(ω) the following iteration was used,
K
Wi+1 (ω) = η diag hΦ(Y(ω, t))YH (ω, t)it
X 

x(t) = A(k)s(t − k), (1)
− hΦ(Y(ω, t))YH (ω, t)it (WiH (ω))−1 + Wi (ω),

k=0 (9)
(10)
where {A(k)} is a sequence of n×m matrices. For simplicity,
we assume that m = n and background noise is negligible. In

where Φ Y(ω, t) ≡ [Φ(Y1 (ω, t)), . . . , Φ(YL (ω, t))]T and
one of experiment we used three-sensor-three-source configu- (R)
ration which consequently form 3 × 3 square matrix, Φ(Y1 (ω, t)) ≡ [1 + exp(−Yl (ω, t))]−1 + j · [1 +
(1)
exp(−Yl (ω, t))]−1
x1 a11 a21 a13 s1
" # " #" #
x2 = a21 a22 a23 s2 (2)
x3 a31 a32 a33 s3 4 F0 E STIMATION
One of the characteristic of signal is frequency. A sig-
where x is the observation, measured from microphone array, nal may have frequencies in spectrum range, but the funda-
s is sources and A is the mixing matrix. The experiment was mental frequency often give an a specific information about
illustrated on Fig. 2. the signal. We, in this section, consider instantaneous fre-
Source separation is a problem to estimate the sources sig- quency framework to estimate F0 , a function to quantitatively
nal from its mixture observations without prior information of ascertain the degree of regularity of the harmonic structure of
 Fig. 2: Multichannel Recording Using Microphone Array
the analyzed sound signal. The fundamental frequency will
be used to characterize the sound pattern of machine sound.
Then, the fundamental frequency data can be used as input
for fuzzy system to automatically determine the condition of
machine.
Instantaneous frequency, which is defined as the derivative
of phase with respect of time, is a novel tool to estimate time-
varying parameter with high accuracy. Using the fact that the
instantaneous phase angle of the input sequence is the (un-
wrapped) angle of the analytic signal, the instantaneous fre-
quency is the rate of change of the instantaneous phase angle
with respect to time. First, the derivation will depart from win-
dowed Fourier transform point of view to estimate the instan-
taneous frequency. By means of the notion of instantaneous
frequency amplitude spectrum, then the harmonic structure of
signal can be revealed to determine the fundamental frequency
[4]. This illustration on Fig. 3 show how to compute F0 based
on instantaneous frequency. The left figure is definition of
the instantaneous frequency amplitude spectrum (IFAS). The
right figure shows an example of STFT (up) and its discrete
IFAS spectrum (down). As we can seen, the F0 based in IFAS
have sharper harmonics than that of in STFT. The F0 data will
be used to analyze the match signal between original signal
and estimated signal. The matched value of F0 estimation be-
tween two signal means that it is the estimated signal. The
value of F0 then was used to build fault identification using
fuzzy system.
Fig. 3: F0 Estimation Based On Instantaneous Frequency [4]
5 P ROPOSED F UZZY I DENTIFICATION
S YSTEM
Before we design the Fuzzy identification system, first,
we have identified some machine condition commonly occurs
in industrial setting. We recorded the machine’s sounds with
prior knowledge of the condition for validation and perfor-
mance evaluation. The F0 data then used to build the fuzzy
identification as shown on Fig. 4. Due to the frequency of
machine is not single, but some frequency appears as in Fig.
Fig. 4: Proposed Identification System
5, we includes those frequency into fuzzy rules. The the fuzzy
rules for machine fault identification are shown below.
Fuzzy IF-THEN rules:
• If F0 =32.53-69.67 and F1 =1757-1789 and F2 =2618-
2696 then the machine is NORMAL
• If F0 =27.62-58.28 and F1 =995-1005 and F2 =1732-1808
then the machine is UNBALANCE
• If F0 =21.31-67.62 and F1 =1764-1782 and F2 =2501-
2697 then the machine is MISALIGNMENT
• If F0 =22.17-117.24 and F1 =200.50-285.00 and F2 =
303.90 - 379.80 then the machine is BEARING FAULT
The rules show that we used three frequency as input for
fuzzy system. The implementation of the fuzzy system is to
identify whether machine is normal, unbalance, misalignment
or bearing fault. Because we use instantaneous frequency ap-
proach to estimate fundamental frequency so the frequency
is changed with respect to time. It resulted the fundamental
frequency has range as we used in fuzzy rules above. The us-
ing of fuzzy system will make easier than direct analysis of
instantaneous frequency to determine the machine condition.
6 R ESULTS AND D ISCUSSION
The data were recorded and digitized with a multichannel
24-bit audio ADC with 44.1kHz sampling frequency to avoid
aliasing in the anechoic chamber to prevent background noise.
The data were then saved into .wav format with PCM audio
coding. We downsampled the data to 8kHz right before fed
into the proposed technique to shorten the calculation time.
The baseline data was used as a control and the result of sep-
aration was compared to it by means of its fundamental fre-
quency. The baseline data come from single-channel record-
ing of each machine condition: normal, unbalance, misalign-
ment and bearing fault. The spectrogram of baseline data on
Fig. 5 shows machine sound characteristic in time, frequency
and amplitude. The x-axis is time, y-axis is frequency and
z-axis is amplitude. The color of spectrogram also represents
sound pressure level in each time and frequency. The red color
indicates a high frequency and the yellow is low frequency.
The Fig. 4 also show the separation on underdetermined
condition, where the number of sensors less than the number
of sources. Blind sound separation works on this problem to
get three estimated signal. The example of estimated signal
for unbalance condition is shown on Fig. 6.
On fig. 5(a), it can be seen clearly that on the normal
condition the machine emits low frequency. The red color
dominated in low frequency region and yellow in the upper
frequency region. In this case, the normal machine has av-
erage frequency at 51 Hz, between 1000-1300 Hz, 1770 Hz.
Fig 5(b) is spectrogram of unbalance machine. It shows that
there are increment frequency around centre of the spectro-
gram (more red color exists). The unbalance machine in this

Fig. 5: Spectrogram of Baseline Data
case has fundamental frequency at normal plus 1990 Hz. Also
the amplitude increase at frequency 1000 Hz and 1770 Hz.
Fig.5(c) shows misalignment condition. The red color appear
at high frequency, as well as at the centre frequency. In this
condition the fundamental frequency were increased at plus
2500, 3400, 5100 and 5300 Hz. Fig.5(d) depicts bearing fault.
The red color dominated at the all frequency that indicated the
amplitude increase near to all frequency. The highest ampli-
tude at this case also from instantaneous frequency informa-
tion give average fundamental frequency at 73 Hz, 250 Hz dan
350 Hz.
The instantaneous diagram (ifgram) on fig. 6 show that
the real frequency is not single, but changes against time. The
fundamental frequency above is average of the instantaneous
frequency. We use first three harmonics to identify machine
condition using fuzzy system. Fig. 6 actually show the origi-
nal and estimated signal of unbalance condition. It can be seen
from figure above that estimated signal from unbalance con-
dition very similar to the original source signal. On the figure,
the estimated of unbalance signal is similar and the amplify-
ing occur at 1770 and 1990 Hz from normal condition, it can
be caused by signal from mass adding on unbalance condition.
The sound pattern of estimated signal blurred so it can iden-
tify signal clearly. But more detailed, the lowest frequency
still can be viewed. Because all of condition have fundamen-
tal frequency at low frequency so it too difficult to diagnosis
that condition in real world application later. The solution for
this problem is the use of first three harmonics to determine
machine condition by fuzzy system its fundamental frequency
data.
The evaluation performance of this experiment also can be
obtained from fundamental frequency data. The more similar
estimated signal to original signal, the higher performance it
has. The real condition of machine compared the result of
identification system also can be used as validation of the pro-
posed system.
7 C ONCLUSION
Based on our experiment on machinery fault diagnosis us-
ing blind sound separation and proposed fuzzy system, it can
be concluded that:
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Fig. 6: Comparison of Original and Estimated Signal For Unbalance Condi-
tion
1. Machinery sounds can be separated using blind sound
separation, for evaluation we used fundamental fre-
quency estimation of matched signal between original
signal and estimated signal.
2. Machinery fault diagnosis can be obtained by sound pat-
tern analysis using instantaneous frequency to determine
fundamental frequency each condition. In this research,
normal motor condition have frequency at 51 Hz, be-
tween 1000-1300 Hz, 1770 Hz and 2650 Hz, unbalance
at 46 Hz, 1000 Hz, 1770 Hz and 1990 Hz, misalignment
at normal frequency plus 3400 Hz, 5100 and 5300 Hz.
The last, bearing fault at 73 Hz, 250 Hz dan 350 Hz.
3. The fundamental frequency data can be used to build ma-
chinery fault identification to simply fault types detec-
tion.
We are working on reducing the number of sensors that pro-
vides more flexibility without imposing a square separation
matrix. This will allow the operator to cover wider or similar
area with less sensor, and yet without sacrificing the measure-
ment accuracy.
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