An automatic and robust features learning method for rotating machinery fault diagnosis based on contractive autoencoder

Because of their cross-functional nature in the company, enhancing Production Planning and Control (PPC) functions can lead to a global improvement of manufacturing systems. With the advent of the Industry 4.0 (I4.0), copious availability of data, high-computing power and large storage capacity have made of Machine Learning (ML) approaches an appealing solution to tackle manufacturing challenges. As such, this paper presents a state-of-the-art of ML-aided PPC (ML-PPC) done through a systematic literature review analyzing 93 recent research application articles. This study has two main objectives: contribute to the definition of a methodology to implement ML-PPC and propose a mapping to classify the scientific literature to identify further research perspectives. To achieve the first objective, ML techniques, tools, activities, and data sources which are required to implement a ML-PPC are reviewed. The second objective is developed through the analysis of the use cases and the addressed characteristics of the I4.0. Results suggest that 75% of the possible research domains in ML-PPC are barely explored or not addressed at all. This lack of research originates from two possible causes: firstly, scientific literature rarely considers customer, environmental, and human-in-the-loop aspects when linking ML to PPC. Secondly, recent applications seldom couple PPC to logistics as well as to design of products and processes. Finally, two key pitfalls are identified in the implementation of ML-PPC models: the complexity of using Internet of Things technologies to collect data and the difficulty of updating the ML model to adapt it to the manufacturing system changes.

Machine learning applied in production planning and control: a state-of-the-art in the era of industry 4.0

Induction motor (IM) drives, specifically the three-phase IMs, are a nonlinear system that are difficult to explain theoretically because of their sudden changes in load or speed conditions. Thus, an advanced controller is needed to enhance IM performance. Among numerous control techniques, fuzzy logic controller (FLC) has increasing popularity in designing complex IM control system due to their simplicity and adaptability. However, the performance of FLCs depends on rules and membership functions (MFs), which are determined by a trial-and-error procedure. The main objective of this paper is to present a critical review on the control and optimization techniques for solving the problems and enhancing the performance of IM drives. A detailed study on the control of variable speed drive, such as scalar and vector, is investigated. The scalar control functions of speed and V/f control are explained in an open- and closed-loop IM drive. The operation, advantages, and limitations of the direct and indirect field-oriented controls of vector control are also demonstrated in controlling the IM drive. A comprehensive review of the different types of optimization techniques for IM drive applications is highlighted. The rigorous review indicates that existing optimization algorithms in conventional controller and FLC can be used for IM drive. However, some problems still exist in achieving the best MF and suitable parameters for IM drive control. The objective of this review also highlights several factors, challenges, and problems of the conventional controller and FLC of the IM drive. Accordingly, the review provides some suggestions on the optimized control for the research and development of future IM drives. All the highlighted insights and recommendations of this review will hopefully lead to increasing efforts toward the development of advanced IM drive controllers for future applications.

Optimization techniques to enhance the performance of induction motor drives: A review

Preventing induction motors (IMs) from failure and shutdown is important to maintain functionality of many critical loads in industry and commerce. This paper provides a comprehensive review of fault detection and diagnosis (FDD) methods targeting all the four major types of faults in IMs. Popular FDD methods published up to 2010 are briefly introduced, while the focus of the review is laid on the state-of-the-art FDD techniques after 2010, i.e. in 2011–2015 and some in 2016. Different FDD methods are introduced and classified into four categories depending on their application domains, instead of on fault types like in many other reviews, to better reveal hidden connections and similarities of different FDD methods. Detailed comparisons of the reviewed papers after 2010 are given in tables for fast referring. Finally, a dedicated discussion session is provided, which presents recent developments, trends and remaining difficulties regarding to FDD of IMs, to inspire novel research ideas and new research possibilities.

A review and comparison of fault detection and diagnosis methods for squirrel-cage induction motors: State of the art.

This paper presents a novel approach on motor current signature analysis (MCSA) for broken bar fault detection of induction motors (IMs), using as input the current signal measured from one of the three motor phases. Independent component analysis (ICA) is used over the Fourier-domain spectral signals obtained from the input and its autocorrelation function. The standard deviation of spectral components within a region of interest (ROI) of an ICA signal output was found to exhibit substantial differences between damaged and healthy motors. Separation of the ROI in one, two, and three sectors leads to an improved extraction of feature vectors, which are further fed into a neural network for classification purposes. The assessment of the proposed method is carried out through several experiments using two damage levels (broken bar and half broken bar) and two load motor conditions (50% and 75%), with a classification accuracy ranging from 90% to 99%. The contribution of this paper lies in a new technique of signal processing for ICA-based feature extraction in a 3-D feature space for IM fault diagnosis.

An Approach on MCSA-Based Fault Detection Using Independent Component Analysis and Neural Networks

Canonical Variable Analysis and Long Short-term Memory for Fault Diagnosis and Performance Estimation of a Centrifugal Compressor

A study on helicopter main gearbox planetary bearing fault diagnosis

The objective of condition monitoring of induction machines is to detect the incipient stage of a fault before serious damage occurs with high associated cost. Although the condition monitoring techniques have been intensively investigated in the last decades, research is still carried out in reducing cost and improving accuracy. This paper proposes a novel method that enables efficient and accurate monitoring of the stator winding circuit fault. The proposed method is based on the sparse grid optimization method applied in the least squares estimation of the circuit parameters that characterize the condition of a fault incipient. The kernel of the method is the efficient search for the objective function minimum on the grid created by using the hyperbolic cross points (HCPs). The system cost and complexity are minimized since the proposed method only requires voltage and current signals recorded at a machine terminal without any invasive or additional hardware circuitry. The proposed HCP algorithm is robust to supply voltage unbalance and motor loading state. The validity and effectiveness of the proposed scheme is experimentally tested on a three-phase 800-W 380-V induction motor.

Condition Monitoring of an Induction Motor Stator Windings Via Global Optimization Based on the Hyperbolic Cross Points

Inaccurate motor parameters can lead to an inefficient motor control. Although several motor estimation methods have been utilized to estimate motor parameters, it is still challenging to ensure a good level of confidence in the estimation. In this paper, we propose a novel offline induction motor parameter estimation method based on sparse grid optimization algorithm. The estimation is achieved by matching the response of machines mathematical model with recorded stator current and voltage signals. This approach is noninvasive as it uses external measurements, resulting in reduced system complexity and cost. A globally optimal point was found by sampling on the sparse grid, which was created using the hyperbolic cross points and additional heuristics. This has resulted in reducing the total number of search points, and provided the best match between the mathematical model and measurement data. The estimated motor parameters can be further refined by using any local search method. The experimental results indicate a very good agreement between estimated values and reference values.

Induction Motor Parameter Estimation Using Sparse Grid Optimization Algorithm

Determining prognosis for rotating machinery could potentially reduce maintenance costs and improve safety and availability. Complex rotating machines are usually equipped with multiple sensors, which enable the development of multidimensional prognostic models. By considering the possible synergy among different sensor signals, multivariate models may provide more accurate prognosis than those using single-source information. Consequently, numerous research papers focusing on the theoretical considerations and practical implementations of multivariate prognostic models have been published in the last decade. However, only a limited number of review papers have been written on the subject. This article focuses on multidimensional prognostic models that have been applied to predict the failures of rotating machinery with multiple sensors. The theory and basic functioning of these techniques, their relative merits and drawbacks and how these models have been used to predict the remnant life of a machine are discussed in detail. Furthermore, this article summarizes the rotating machines to which these models have been applied and discusses future research challenges. The authors also provide seven evaluation criteria that can be used to compare the reviewed techniques. By reviewing the models reported in the literature, this article provides a guide for researchers considering prognosis options for multi-sensor rotating equipment.

https://journals.sagepub.com/doi/pdf/10.1177/1687814016685004

Fang Duan

Papers

Canonical Variable Analysis and Long Short-term Memory for Fault Diagnosis and Performance Estimation of a Centrifugal Compressor

A study on helicopter main gearbox planetary bearing fault diagnosis

Condition Monitoring of an Induction Motor Stator Windings Via Global Optimization Based on the Hyperbolic Cross Points

Induction Motor Parameter Estimation Using Sparse Grid Optimization Algorithm

Multidimensional prognostics for rotating machinery: A review