Detecting anomalies in electrical equipment operation

Abstract: A system and method for ascertaining anomalies in electrical equipment includes computing and processing a set of Fast Fourier Transforms (FFT's) of the supply current waveforms for an apparatus known to be in a normal condition to crete a feature set of input vectors. The input vector assignments for all possible cluster groupings 1 to n are derived using Ward's method. The method includes computing the Approximate Weight of Evidence (AWE) for each cluster grouping then selecting that count associated with a maximum AWE and designating this count as s. For each cluster in each grouping 1 to s, the method finds the member vector farthest from the cluster's centroid and defines this as the cluster's radius. A single input sample for a motor under supervision is read in, following by computing and processing an FFT based on the input sample for a newly generated feature vector is inside any of the clusters 1 through s as defined for each cluster by its respective radius, and if not, outputting a warning signal.

Description: The present invention relates to detecting anomalies in electrical equipment operation, and in particular anomalies in electric motors. Electric motors are used in very large numbers in many phases of industry. Unexpected electric motor failure is a highly undesirable occurrence since it may result in a host of unwanted and sometimes unacceptable possibilities, including inconvenience, disruption of industrial operations, product loss, safety problems and the like. The present application discloses subject matter related to the subject matter of patent application Serial NO. 08/269466 entitled A NEURAL NETWORK AUTO-ASSOCIATOR AND METHOD FOR INDUCTION MOTOR MONITORING, filed in the names of Thomas Petsche et al. on June 30, 1994 and of patent application Serial No. 08/269465 entitled A RADIAL BASIS FUNCTION NEURAL NETWORK AUTO-ASSOCIATE AND METHOD FOR INDUCTION MOTOR MONITORING, filed in the names of Thomas Petsche et al. on June 30, 1994. Induction motors are particularly desirable in many industrial applications because of a number of advantages, including no need of a commutator, a simple construction, generally suitable torque characteristics, essentially constant speed, and low electrical and acoustic noise. Generally, in industrial settings today, induction motor health is either unmonitored until a problem develops, or monitored on a random basis by simply having a mechanic listen to the motor for the presence of excessive or unusual noise. Induction motor mechanical problems are divided into two broad categories; rotor faults, and shaft speed oscillations. If for example the rotor fault is due to asymmetry, the airgap flux will be perturbed at a frequency equal to the speed of rotation of the motor shaft. The frequencies of the spectral components present in the airgap flux are given by the following expression where F 1 is the line frequency, p the number of poles, k a positive integer, and s the per unit slip which represents the speed difference between the rotor and the magnetic field. F = F 1 ((2 k / p )(1 -s )± s ) For the case where the fault is due to an oscillation in the shaft speed of the motor a slightly different expression is used to find the fault harmonics. F = F 1 ((2 k / p )(1- s )±1) Among the disadvantages of present motor-health-monitoring method are that they rely on human judgment and therefore tend to be subjective, and that if and when a problem is detected it may already be too late to avert unscheduled downtime for maintenance or replacement. Accordingly, it is desirable that incipient problems with a motor be detected in the developing stage before they cause failure in operation with undesirable consequences. It is also desirable that any monitoring for nascent failure modes be done with a minimum of interference with the motor's operation and a low cost, particularly since the cost of industrial induction motors is relatively low in what is a competitive market. It is known that the waveform of the supply current to an induction motor exhibits components which contain information on the operation of the motor and the nature of its useful load, including data possibly indicative of anomalous operation, such as an incipient fault or problem. It is therefore desirable to derive useful prediction information from data samples obtained from the motor supply current waveform. The details of obtaining such samples are described in the present specification. However, more detail on this aspect is obtainable from the above-identified patent applications of Petsche. It is also desirable to classify data samples, which are representative of an induction motor's health as coming from either a healthy motor or an unhealthy motor. This function is preferably performed with the motor on-line in an industrial setting such that the output of the anomaly detector may be used as a guide to maintenance personnel. It is also desirable to solve the problem of dealing with the uncertainty of induction motor failure and the difficulty associated with unscheduled downtime for motor maintenance or replacement. It is further desirable to provide the benefit of an early warning system for motor failure so as to alert maintenance personnel that an induction motor is starting to develop a problem, thereby providing a grace period within which maintenance may be scheduled in a more timely fashion. Work on induction motor condition monitoring using frequency domain analysis is well documented in, for example, P.J. Tavner and J. Penman, "Condition Monitoring of Electrical Machines", Research Studies Press Ltd., Letchworth, Hetfordshire, England, 1987; I. Morito and H. Okitsu, "Signature frequency analysis for diagnosis of induction motor systems", Electrical Engineering in Japan, 109(4), 1989; and G.B. Kliman and J. Stein, "Induction motor fault detection via passive current monitoring", In International Conference on Electrical Machines, August 1990, and research has been carried out in this area. Similarly, the use of cluster analysis is well known and is extensively documented in, for example, G.J. McLachlan, "The Classification and Mixture Maximum Likelihood Approaches to Cluster Analysis", Chapter o, pp. 199-208, North-Holland Publishing Company, 1982; D. Anderson, M. Aitkin and J. Hinde, "Statistical modelling of data on teaching styles", In Journal of Royal Statistical Society, pp. 419-461, 1981; and J. Zupan, "Clustering of Large Data Sets", Research Studies Press, Chichester, 1982. See also, for example, L. Kaufman and P.J. Rousseeuw, "Findings Groups In Data, An Introduction to Cluster Analysis", Chapter #5, Wiley-Interscience, 1990, pp. 230-234; and H.C. Romesburg, "Cluster Analysis for Researchers", Chapter #9.4, pp. 129-135, Robert E. Krieger, 1990. The document Schoen R R et al: 'An Unsupervised, On-line System for Induction Motor Fault Detection using Stator Current Monitoring' IEEE Transactions on Industry Applications, vol. 31, no. 6, 1 November 1995, pages 1280-1286 discloses a method for on-line motor fault detection which comprises sampling the stator current, forming clusters using a neural network clustering algorithm and, if during normal operation a sample falls outside of the clusters, "tagging" this sample as a potential fault. However, a rule-based frequency filter stage is required before the clustering stage. The rules which determine which frequencies are to be passed to the neural network require the intervention of an expert person. The document Beilharz J et al: 'Statistische und neuronale Verfahren zum nicht überwachten Klassifikatorenentwurf in der Motorendiagnose' Automatisierungstechnik - at, vol. 43, no. 1, 1 January 1995, pages 46-53 discloses statistical cluster analysis in the diagnosis of electrical motors. However, the number of clusters formed is predefined which requires an "a priori" knowledge of the electrical motor to be tested. The present invention is defined in the independent claims. Further aspects of the invention are defined in the dependent claims. The number of clusters, is determined using an iterative procedure called the approximate weight of evidence (AWE), a Bayesian approach that uses the log likelihoods to estimate the probability for the number of clusters. See, for example, J.D. Banfield and A.E. Raftery, "Model-based gaussian and non-gaussian clustering", Biometrics, 1992. Once this initial representative sample of healthy motor data is grouped, new data vectors are tested by measuring their distance from the centroid of each healthy motor data cluster. If a new data point falls within any healthy data p-dimensional spheroid, whose radius is determined by the point farthest from the clusters centroid, that data is not considered novel, and therefore is labelled as coming from a healthy motor. If however, the new data point falls outside of every healthy motor data cluster, it is considered novel, and therefore indicative of a motor problem. For a better understanding of the invention, and to show how the same may be carried into ettect, rererence will now be made, by way of example, to the accompanying drawings, in which:- Figure 1 shows a flow diagram of a method in accordance with the invention; Figure 2 shows details of a clustering procedure utilized in the invention; Figure 3 shows an example of clustering results obtained in accordance with the invention based on actual induction motor data; Figure 4 shows a data set including 40 2-dimensional input vectors; Figure 5 shows a plot of the approximate weight of evidence calculated for the data shown in Figure 4; Figure 6 is a plot of cluster assignments; and Figure 7 shows a system in accordance with the invention in block diagrammatic form. Referring to Figure 1, the upper six boxes of the flow diagram outline the steps involved in finding the healthy motor groups, computing the approximate weight of evidence, and calculating the size of each healthy motor cluster. These steps comprise the training phase. These steps comprise initializing (Step 1), reading in "healthy" motor training set data (Step 2), computing a set of Fast Fourier Transforms (FFT's) based on training set data which is then processed as required to create a feature set (Step 3). The process then continues with the step of calculating all possible input vector assignments for cluster groupings 1 to n using Ward's clustering method (Step 4), computing the Approximate Weight of Evidence (AWE) for cluster grouping 1 to n and selecting the grouping associated with a maximum AWE and designating this count as s (Step 5). The "dendritic" progress of the clustering process is therefore truncated at the level s, this being the optimal choice under the criteria of the AWE algorithm used. The process continues with the step of, for each cluster 1 to s, finding the member vector farthest from the cluster's centroid and identifying this as the cluster's radius (Step 6). Once the healthy motor clusters are constructed, the procedure enters the on-line monitoring phase as outlined by the steps in the three lower boxes of the flow diagram. As shown in Figure 1, these steps comprise reading in a single input sample, computing the FFT, and generating a feature vector (Step 7), checking whether the newly generated feature vector is inside any of the healthy data clusters (Step 8), and outputting a warning signal to maintenance personnel (Step 9). If the answer in step 8 is affirmative, the system returns to step 7; otherwise, the process continues through step 8. When step 9 outputs the warning signal, the system returns to step 7 and continues. Accordingly, in this phase, as set forth above, input samples of induction motor stator current are processed to create feature vectors one-at-a-time. The Euclidian distance between the feature vector and each healthy motor cluster centroid is then calculated. This is where novelty detection is used. If the feature vector falls within any healthy motor cluster, the procedure simply loops around to read the next sample. If however, the feature vector does not fall within any of the healthy motor clusters, it is considered novel since it is outside of the healthy groups, and a single is outputted to alert maintenance personnel. Details of the actual clustering procedure used in the present exemplary embodiment are shown in the diagram in Figure 2. Reference is made to the cited literature relating to Ward's Clustering Algorithm and to the following description of the Approximate Weight of Evidence for the definition of symbols used herein. As is well known, Ward's clustering algorithm is a hierarchial-agglomerative method which provides the input observation, or input vector, assignments for all possible groupings from 1 to n where n is the total number of observations. Some way is required therefore, to act as a guide in choosing the number of clusters, or groups. One approach is to use the approximate weight of evidence (AWE) which uses the log likelihoods to estimate the probability for the number of clusters being s, where s is between 1 and n. The AWE uses the covariance, or cross-product, matrix: W k = Σ iεC k (x i - x k )(x i - x k ) T and focuses on the variance tr (W k ) The AWE is a function of the likelihood: where c is a constant, n is the number of observations and p is the number of parameters. Trace of W is defined as: s is the number of clusters The AWE can be calculated as follows. If clusters I and j are merged at step r, the value of the likelihood at step r+1 is given by: The difference in log likelihoods is: In going from step r to step r+1, the change in the approximate weight of evidence is: where n r,r+1 is the number of observations in the merged cluster, and σ r the number of parameters The approximate weight of evidence of s clusters is: We choose the number of clusters that maximises F s ; s* = argmax s F s In Figure 2, the steps comprise: following an initialising Step 1, setting K (the number of groups considered) equal to n (the number of input vectors) (Step 2), setting the "best value" Z[pk_1, qk_1, k-1] equal to some initial large value and putting I equal to the smallest j equal to the first active identification number (Step 3), setting j equal to the first active identification number greater than I (Step 4), computing Z[I, j, k-1] associated with the hypothesized union of sets I and j (Step 5), determining whether Z[I, j, k-1] is better than the best value z[pk_1, qk_1, k-1] up to this comparison (Step 6); if the answer is yes, this is followed by Step 7, replacing the old value of Z[pk_1, qk_1, k-1] by Z [I, j, k-1] and making pk_1=I and qk_1=j and proceeding to Step 8; if the answer is no, this is followed by Step 8, ascertaining whether j is equal to the last active identification number (Step 8); if the answer is no, then set j equal to the next higher active identification number (Step 9), and return to Step 5; if the answer is yes, proceed to Step 10 to determine whether I is equal to the next higher active identification number (Step 11) and return to Step 4; if yes, proceed to Step 12 wherein a best union of 2 sets has been found and is identified by the identification numbers pk_1 and qk_1, the value associated with their union being Z[pk_1, qk_1, k-1], then to Step 13 to identify the new union by the number pk_1 and make the identification number qk_1 inactive, then calculate trace values for 2 clusters that were merged and for the new cluster which was formed by the merge (Step 14), then compute lambda_r and E_r for this step in the clustering procedure (Step 15), then determine whether k (the number of groups under consideration) is equal to 2 (Step 16); if not, set k equal to k-1 (Step 17) and return to Step 2; if the answer is yes, proceed to calculate the approximate weight of evidence for all steps from 1 to n-1 (Step 18), and so arrive at the Finish, (Step 19). Figure 3 presents an example of clustering results based on actual induction motor data gathered by a data acquisition system. Data samples can preferably be taken at a rate of 1920 Hz, giving harmonic energies approximately every 0.5 Hz between 0 and 960 Hz. In this example 10 clusters were suggested by the AWE. In Figure 3, each of the lines labelled 1-10 represent a cluster formed of the cluster members on that line. The test conditions are set forth in the test conditions at the top of Figure 3. Thus, inputs are for a balanced motor, with 10 FFT's per load condition. Each FFT is an average of 12 "raw" FFT's. Forty-two input features are used in the range of 0Hz - 58.59Hz, each feature being an average of 3 frequencies spanning 1.4036Hz. The numbered clusters correspond respectively to the 10 loads the induction motor was driving while the data was being gathered, as listed in the test conditions in Figure 3. Thus vectors 1-10 correspond to a load condition of 1/2 the rated constant load for the motor, vectors 21-30 correspond to a rated load condition varying sinusoidally, vectors 91-100 correspond to the rated load intermittently applied in square wave fashion at a rate of 30Hz, and so forth for the other vectors, as indicated. Figure 4 lists a 40x2 data set, different from the data in Figure 3. Each of the 40 vectors comprises the decibel value at 2 separate frequencies provided by the FFT. These frequencies were found to be useful in distinguishing induction motor faults for this particular set of data. In this experiment the clustering program was trained on all 40 input vectors in order to determine the effectiveness of the 2 frequencies in separating the fault groups. Figure 5 plots the approximate weight of evidence calculated for the data of Figure 4. It is apparent that a broad peak occurs at around 7 clusters. Naturally, other clustering criteria may be utilized. The number of clusters is necessarily a compromise between on the one hand the similarity of members of a cluster, which is desirably maximised, and on the other hand, the dissimilarity or distinctness of the clusters themselves which is also desirably maximised. Figure 6 is a plot of the cluster assignments corresponding to this data. Figure 7 shows a system in accordance with the invention in block diagrammatic from. An induction motor 10 drives a load device 12 which, for the purposes of developing data, may be programmable and variable. The power supply leads 14 to motor 10 pass through a current sampling device 16, from which digital information on current samples is supplied to a programmed computer 18. Computer 18 is also coupled to a warning or signalling device 20. While the invention has been described by way of an exemplary embodiment, it will be understood by one of skill in the art to which it pertains that various changes and modifications can be made to achieve the same result whilst employing the same inventive concept. It will also be understood that, while the exemplary application described is directed to motors, the invention is just as well applicable to other electrical devices from which an electrical signal is obtainable which exhibits information useful in detection anomalous performance or conditions. The electrical signal may be from the supply current but need not be. It may be a representative current or voltage anywhere in the device. Thus, for example, a different clustering algotithm, other than Ward's can be utilized. Furthermore, a different rule can be used from the Approximate Weight of Evidence herein applied. The width of spectral windows, the spectral averaging technique, and the Euclidean distance criterion are all susceptible of replacement by other convenient alternatives. The exemplary implementation herein disclosed is not intended to be limiting of the invention.

Claims: A method for detecting operating anomalies in an electrical apparatus, the method comprising: in a training phase, obtaining a set of data samples indicative of signal waveforms of electrical signals of a healthy electrical apparatus; processing the set of data samples in order to produce at least one data cluster, the or each cluster having a centroid and a maximum radius from the centroid which define the position and extent of the cluster concerned, the or each such cluster defining a normal operating condition of the electrical apparatus; in a monitoring phase, obtaining a detected data sample indicative of a signal waveform sample for the electrical apparatus when the apparatus is in use; comparing the detected data sample with said data clusters, in order to determine if that detected data sample falls within a data cluster; and detecting and comparing a new signal waveform sample if the detected data sample falls within a data cluster, or producing a warning signal if the detected data sample does not fall within a data cluster. A method as claimed in claim 1, wherein the processing step includes producing Fast Fourier Transforms, FFTs, of the data samples. A method as claimed in claim 1 or 2, wherein the processing step includes calculating input vector assignments using Ward's method. A method as claimed in claim 1, 2 or 3, wherein the processing step includes producing a plurality of clusters, calculating the Approximate Weight of Evidence, AWE, for the clusters, and selecting the cluster having the maximum AWE. A method as claimed in claims 1 to 3, wherein the processing step includes providing a plurality of clusters and selecting clusters in accordance with a Bayesian approach using log likelihoods. A method as claimed in claim 5, wherein the processing step includes using Euclidean distances between cluster centroids. A method as claimed in any one of the preceding claims, wherein the detected data sample is subjected to a FFT process. A method as claimed in any one of the preceding claims, wherein the electrical apparatus is an electric motor. A method as claimed in claim 8, wherein the method is implemented by a computer. A method as claimed in claim 9, wherein the FFTs are based on waveforms of the electrical signal samples from a healthy electric motor, thus creating a feature set of input vectors. A method as claimed in claim 10, wherein the processing step includes calculating all possible input vector assignments for clusters 1 through n using Ward's method, where n is the number of p-dimensional input vectors. A method as claimed in claim 11, wherein the processing step includes calculating the AWE for clusters 1 through n. A method as claimed in claim 12, wherein the processing step includes designating the cluster count having the maximum AWE as s and for each cluster 1 through s, finding the vector farthest from the cluster's centroid and defining this as the cluster's radius. A method as claimed in claim 13, wherein the step of obtaining a set of data samples for a healthy electric motor comprises sampling current flowing in a winding of the electric motor. A method as claimed in claim 14, wherein if the detected data sample does not fall within a data cluster then said detected data sample is labelled as indicative of a motor problem. A method a claimed in claim 15, wherein the method step using Euclidean distances between cluster centroids, comprises using a distance metric which maximises the sum of the squared Euclidean distances. A system for detecting operating anomalies in an electrical apparatus, the system comprising: means for obtaining a set of data samples indicative of signal waveforms of electrical signals of a healthy electrical apparatus; means for processing the set of data samples in order to produce at least one data cluster, the or each cluster having a centroid and a maximum radius from the centre which define the position and extent of the cluster concerned, the or each such cluster defining a normal operating condition of the electrical apparatus; means for obtaining a detected data sample indicative of a signal waveform sample for the electrical apparatus when the apparatus is in use; means for comparing the detected data sample with said data clusters, in order to determine if that detected data sample falls within a data cluster; and means for detecting and comparing a new signal waveform sample if the detected data sample falls within a data cluster, or producing a warning signal if the detected data sample does not fall within a data cluster.

Inventors: HANSON STEPHEN J, MARCANTONIO ANGELO R, PETSCHE THOMAS, HANSON, STEPHEN J., MARCANTONIO, ANGELO R., PETSCHE, THOMAS
Applicants: SIEMENS CORP RES INC, SIEMENS CORPORATE RESEARCH, INC.
Application year: 1997
Main classification: G01R31
IPC codes: G01R31