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Applied Acoustics 173 (2021) 107661

Contents lists available at ScienceDirect

Applied Acoustics
journal homepage: www.elsevier.com/locate/apacoust

Technical note

An efficient acoustic-based diagnosis of inter-turn fault in interior mount


LSPMSM
Luqman S. Maraaba a, Azhar M. Memon a,⇑, M.A. Abido b,c, Luai M. AlHems a
a
Center for Engineering Research, Research Institute, King Fahd University of Petroleum and Minerals, Dhahran, Saudi Arabia
b
Department of Electrical Engineering, King Fahd University of Petroleum and Minerals, Dhahran, Saudi Arabia
c
K.A.CARE Energy Research & Innovation Center (ERIC), Dhahran, Saudi Arabia

a r t i c l e i n f o a b s t r a c t

Article history: This paper investigates the use of acoustic signals in diagnosing stator inter-turn faults in Line Start
Received 28 May 2020 Permanent Magnet Synchronous Motors (LSPMSMs). Singular spectrum analysis (SSA) is proposed to ana-
Received in revised form 5 August 2020 lyze the acoustic signal for fault detection. The proposed methodology involves collection of experimen-
Accepted 4 September 2020
tal acoustic data using a smartphone from an interior mount LSPMSM under different loading levels,
Available online 10 October 2020
healthy as well as faulty motor cases where different number of turns are shorted to emulate different
fault levels. Acoustic signal for each case is analyzed using SSA, which results in decomposition of the sig-
Keywords:
nal into periodic components and noise. Fast Fourier Transform (FFT) of each component is carried out to
Acoustic
Electric motors
find the unique frequency representative for each case. The results with the proposed methodology show
Faults that it is capable to detect the occurrence of inter-turn fault under different loading levels with the capa-
LSPMSM bility of distinguishing fault severity with readily available acoustic sensor of a smart phone. In addition,
Singular spectrum analysis it is possible to differentiate between the load and no-load modes of operation.
Ó 2020 Elsevier Ltd. All rights reserved.

1. Introduction Most of the previous research studies on the fault diagnosis


were focused on rotor faults and demagnetization [5–10], while
The use of LSPMSM in industrial constant speed applications is few recent attempts addressed stator winding faults [1,11]. Several
in its early stages [1]. It is considered among the most promising parameters are used to identify motor faults, such as motor current
types of motors due to its high efficiency (low CO2 emissions, signature (MCS), instantaneous angular speed (IAS), acoustic signa-
meets the IE4 super-premium efficiency standard [2]), high opera- ture (AS) and surface vibration signature (VS). The use of acoustic
tional power factor, power density, operational torque, low opera- signal in detection of motor faults is inexpensive and non-
tional temperature and self-starting [3,4]. Therefore, LSPMSMs are invasive. A brief review of some of the recent research works on
an excellent choice for reduction in the energy consumption. using them for motor fault detection is presented here.
Due to internal and external stresses such as destruction in the Refs. [12,13] presented the analysis of acoustic signal from syn-
insulation material, inefficient cooling, voltage stress, overloading, chronous motor and DC machine, respectively. Former used line
chemical contamination and partial discharge, motors can experi- spectral frequencies and K-nearest classifier with Minkowski dis-
ence several types of faults, such as inter-turn faults, eccentricity, tance, while later used Symlet wavelet transform and modified
broken bars and demagnetization. These failures cause a significant classifier based on words. In Ref. [14], both broken bars in induc-
loss of revenue and decrease efficiency and reliability of the tion motor and shorted rotor coils in direct motor were investi-
motors. Since the number of LSPMSMs used in the industry is gated using the acoustic signal under different fault severities. In
increasing, the need for maintenance programs is growing consis- their study, the authors used pattern recognition for acoustic data
tently. As such, it is important to develop a diagnosis tool that pre- to detect the abnormalities.
dicts the faults at their early stages [1]. In Ref. [15], the acoustic sensors in smartphones, which are
readily available for low-cost continuous real-time monitoring,
were used in detecting broken bar and dynamic eccentricity in
⇑ Corresponding author. induction motors. It was concluded that the smartphones can be
E-mail addresses: lmaraaba@kfupm.edu.sa (L.S. Maraaba), azhar.memon@ used for preliminary condition monitoring. In Ref. [16], an acoustic
kfupm.edu.sa (A.M. Memon), luaimalh@kfupm.edu.sa (M.A. Abido), mabido@ signal based diagnostic tool for detecting stator winding faults in
kfupm.edu.sa (L.M. AlHems).

https://doi.org/10.1016/j.apacoust.2020.107661
0003-682X/Ó 2020 Elsevier Ltd. All rights reserved.
L.S. Maraaba, A.M. Memon, M.A. Abido et al. Applied Acoustics 173 (2021) 107661

single phase induction motor was developed. Two types of stator Table 1
winding faults were considered; auxiliary winding short circuit Parameters of LSPMSM motor.

fault, and auxiliary-main windings short circuit fault. The authors Parameters Value
used fast Fourier transform to extract the fault related features. Number of Poles 4
They analyzed the application of K-Nearest Neighbor, K-Means Number of turns per stator phase 86  4
clustering, and Linear Perceptron classifiers. Results showed that Number of bars 20
the effectiveness of all the selected classifiers was good. In Ref. Permanent magnet flux Density 1.25 T
Machine rated power 1 hp
[17], a fault-detection tool for broken bar and end-ring fault in a Rated voltage 400 V rms
squirrel cage three phase induction motor was developed. Acoustic Rated frequency 60 Hz
signal, collected by digital voice recorder, was used for the detec- Rated speed 1800 rpm
tion of faults. A Nearest Neighbor classifier and backpropagation
neural network were implemented using a group of extracted fea-
tures from the spectrum of acoustic signals for fault detection. In
Ref. [18], vibration signals with Hilbert-Huang transform were
used for detecting bearing faults. A nonlinear entropy-based fea-
ture extraction approach was used for the tool design. It was con-
cluded that nonlinear entropy-based feature lead to a better
accuracy and superiority of the proposed method compared to
the other methods for fault detection.
To the best of authors’ knowledge, there is no prior work on
using acoustic signals to identify load and inter-turn fault condi-
tion of LSPMSM. Moreover, the distinct characteristics of sounds
produced by various severity levels of these faults in laboratory
tests clearly indicated that there is a potential for effective fault
diagnosis. With this motivation, the objective of this study is to
provide first results on the use of a smart phone to collect acoustic
signals resulting from inter-turn faults under the full-load and no-
load modes of operation with different severity levels, and analyze
this data using singular spectrum analysis (SSA) to identify their Fig. 1. Laboratory LSPMSM experimental setup.
distinct features. Results presented in this note hint towards a
cost-effective way to diagnose the inter-turn faults of LSPMSMs. Different sizes of the inter-turn faults were implemented to the
interior mount LSPMSM used. The measured cases of motor are as
2. Singular spectrum analysis (SSA) follows: (i) healthy case (no shorted turns); (ii) 4 shorted turns;
(iii) 9 shorted turns; (iv) 26 shorted turns; (v) 40 shorted turns.
The main advantage of SSA is that it does not need apriori All test cases were performed at no-load (NL) and full-load (FL)
assumptions about the model structure or any statistical require- (4.0 N.m) with background noise which included the sound of
ments from the signal or time series to be analyzed. This feature other machines operating in the laboratory and human noise. Sta-
and the fact that it can decompose a signal into trend, oscillatory tor inter-turn fault was achieved experimentally by adding six
components and noise has made the technique a standard choice access points to phase-A as shown in Fig. 2, which were labeled
for the time series analysis. SSA can be used as a stand-alone by the letter ki. As an example, to emulate 26 shorted turns, k1
decomposition tool or in combination with other algorithms for and k2 were connected through the resistance (fault resistance).
further improvement of the results. For this work, the components The resistance was used to limit high short circuit current in the
of acoustic signal obtained by SSA are analyzed in the frequency shorted turns. During experiments, all electric data of the motor
domain by using FFT. A component that gives the unique frequency was measured as well as the audible noise was recorded using a
for each case under study is selected for load and fault characteri- smartphone mounted on the motor at 48,000 samples per second
zation. The technique comprises four steps. Firstly, the signal or using waveform capture capability of the circuit monitor.
time-series is structured in a matrix form, called trajectory matrix,
where the number of its rows equals the desired number of com- 4. Results and discussion
ponents in which the signal has to be decomposed. Secondly, sin-
gular value decomposition (SVD) is applied to the trajectory As mentioned before, two cases were studied, i.e., NL and FL
matrix for decomposition. The component matrices (product of (4.0 N.m). Furthermore, each case was studied under no-fault
eigen-vectors and respective singular values), thus obtained, are (healthy) and inter-turn fault conditions, whereby 4, 9, 26, and
then combined to group related, similar, or desired periodicities
or patterns in the signal; grouping the related components refers
to focusing on particular characteristics of the time-series which
would enhance specific periodicity. The last step reconstructs com-
ponent’s time-series from the obtained matrix. For a detailed dis-
cussion and more details, the interested reader can consult [19].

3. Data collection

For this work, a 1.0 Hp interior mount LSPMSM was used and its
parameters are presented in Table 1. A smartphone was used for
collecting the acoustic signal from a faulty machine. The laboratory
experimental setup for performing these tests is shown in Fig. 1. Fig. 2. Fault illustration for LSPMSM experimental setup.

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L.S. Maraaba, A.M. Memon, M.A. Abido et al. Applied Acoustics 173 (2021) 107661

40 turns were shorted to emulate the faulty conditions. The file- 150 Hz. With a different energy distribution along these frequen-
names for each data set are listed in Table 2 and the same will cies, the first component of healthy FL mode shows an additional
be followed throughout this paper. Each file lasted for two seconds 110 Hz frequency, which is prominent with significant energy.
or 96,000 samples at the sampling frequency of 48,000 samples per The results are shown in Figs. 3 and 4, where the time domain
second. observation of the first component shows a larger amplitude and
Before proceeding with SSA, the data was pre-processed; this distortion for FL case as opposed to NL. Here, the data is zoomed
included removing mean from each time-series of the acoustic sig- to the first 20,000 samples to ensure better visualization of wave-
nal and also normalizing them between 0 and 1. For application form characteristics. Unlike NL case, the deviation from sinusoidal
described in this paper, the number of components or window pattern can be attributed mainly to the presence of 110 Hz compo-
length L for SSA was made by the visual inspection of the data nent, which is not a harmonic of 30 Hz. It is obvious that 110 Hz
and trials with various values, whereby the computational time frequency can be used to differentiate between NL and FL condi-
and frequency content of the obtained components were observed; tions in a healthy motor.
L of 200 samples was selected. This takes a reasonable amount of
computational time and results in distinct frequencies for each 4.1.2. 4-turns fault
case. This was followed by conventional SVD, elementary grouping Similar to the healthy case described above, SSA was applied to
and reconstruction by diagonal averaging. Once the components the data of 4-turn shorted fault. The results show a similar behav-
were obtained, FFT was employed to reveal the frequency content. ior to healthy case as shown in Figs. 5 and 6. Higher amplitude and
Python 3.7.4 64-bit was used for implementation of SSA algo- distortions were observed for FL with distinct 110 Hz frequency
rithm on Windows 10 platform with Intel Core i5, 3.4 GHz proces- component in addition to the fundamental 30 Hz and its harmon-
sor and 8 GB RAM. It is worth mentioning that the algorithm for
basic SSA, as described in the literature, took several hours for
completion on this machine even for a smaller window size. This
was due to the grouping and diagonal averaging steps. In order
to efficiently perform these steps, only the first 30 elementary
matrices were selected (out of 200) to go through the averaging
process, as all the components beyond 30 were unstructured noise.
Furthermore, algorithmic changes were made in Python code to
perform fast diagonal averaging.

4.1. No-load and full-load conditions

As a first step, it was necessary to differentiate between the NL


and FL cases in both healthy and faulty conditions. The proposed Fig. 3. First 20,000 samples of the 1st component; window length ‘L’ = 200, samples
SSA algorithm was applied on the acoustic data collected for all ‘N’ = 96000. (a) No-load healthy motor. (b) Full-load healthy motor.

these cases. Then, FFT of the first thirty components was observed
for distinct frequencies pertaining to the load characteristics of the
motor.
To test the applicability of the proposed methodology, the algo-
rithm was applied on multiple windows of the 2 s data with vary-
ing the size and placement of each window. This was done since
different sources of background noise were present at the time of
data collection, which would result in different acoustic character-
istics during the same acoustic file.
In this section, the authors only show results of one of the win-
dows to ensure brevity as the algorithm gives consistent results
regardless of the selected window. In the healthy and faulty condi-
tions, FFT of the first component shows workable features for dif-
ferentiating between the NL and FL modes of operation as Fig. 4. Comparison of the 1st component in time and frequency domain for healthy
illustrated in the following subsections. motor in NL and FL conditions. Only first 20,000 samples are shown here for clarity,
SV stands for Singular Value. (a) Time domain. (b) Frequency domain, 110 Hz
4.1.1. Healthy motor observed for full-load case.

In healthy NL condition the component shows periodicity of


30 Hz along with three to four harmonics at 60, 90, 120 and

Table 2
Filenames of audio data and their description.

Filename Description
nlh No load, healthy motor
nl4 No load, 4 turns shorted
nl9 No load, 9 turns shorted
nl26 No load, 26 turns shorted
nl40 No load, 40 turns shorted
flh Full load, healthy motor
fl4 Full load, 4 turns shorted
fl9 Full load, 9 turns shorted
fl26 Full load, 26 turns shorted
Fig. 5. First 20,000 samples of the 1st component; window length ‘L’ = 200, samples
fl40 Full load, 40 turns shorted
‘N’ = 96000. (a) No-load 4-turn fault. (b) Full-load 4-turn fault.

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L.S. Maraaba, A.M. Memon, M.A. Abido et al. Applied Acoustics 173 (2021) 107661

Fig. 6. Comparison of the 1st component in time and frequency domain for 4-turn Fig. 10. Comparison of the 1st component in time and frequency domain for 26-
shorted motor in NL and FL conditions. Only first 20,000 samples are shown here for turn shorted motor in NL and FL conditions. Only first 20,000 samples are shown
clarity, SV stands for Singular Value. (a) Time domain. (b) Frequency domain, here for clarity, SV stands for Singular Value. (a) Time domain. (b) Frequency
110 Hz for full-load and additional 25 Hz observed for no-load case. domain.

Fig. 7. First 20,000 samples of the 1st component; window length ‘L’ = 200, samples Fig. 11. First 20,000 samples of the 1st component; window length ‘L’ = 200,
‘N’ = 96000. (a) No-load 9-turn fault. (b) Full-load 9-turn fault. samples ‘N’ = 96000. (a) No-load 40-turn fault. (b) Full-load 40-turn fault.

Fig. 12. Comparison of the 1st component in time and frequency domain for 40-
Fig. 8. Comparison of the 1st component in time and frequency domain for 9-turn turn shorted motor in NL and FL conditions. Only first 20,000 samples are shown
shorted motor in NL and FL conditions. Only first 20,000 samples are shown here for here for clarity, SV stands for Singular Value. (a) Time domain. (b) Frequency
clarity, SV stands for Singular Value. (a) Time domain. (b) Frequency domain, domain, where 110 Hz can still be observed despite the fault severity.
110 Hz for full-load case observed.

Table 3
Frequency modes for NL operating mode in the 18th
component of SSA.

Mode – Fault Approx. Frequency [Hz]


No load – Healthy 2750
No load – 4-turn fault 240
No load – 9-turn fault 2450
No load – 26-turn fault 6950
No load – 40-turn fault 3600

ics. However, with 4-turn shorted fault, NL operation shows distor-


tions mainly due to a 25 Hz component with comparable ampli-
Fig. 9. First 20,000 samples of the 1st component; window length ‘L’ = 200, samples tude with that of the 30 Hz. In addition, a difference can be
‘N’ = 96000. (a) No-load 26-turn fault. (b) Full-load 26-turn fault. observed between the original data for healthy case in Fig. 3(a)
and 4-turn fault data in Fig. 5(a), where former shows repetition

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L.S. Maraaba, A.M. Memon, M.A. Abido et al. Applied Acoustics 173 (2021) 107661

Fig. 13. FFT of the 18th component of NL acoustic data, samples ‘N’ = 96000, window length ‘L’ = 200. (a) No-load 4-turn fault at 240 Hz. (b) No-load 9-turn fault at 2450 Hz.
(c) No-load healthy at 2750 Hz. (d) No-load 40-turn fault at 3600 Hz. (e) No-load 26-turn fault at 6950 Hz.

of an envelope as opposed to later. First component for the FL case shaped envelope is followed and the first component does not
shows a higher amplitude variation (Fig. 6(a)) as compared to its show significant distortions from sinusoidal behavior. Moreover,
counterpart in healthy case (Fig. 4(a)). the energy distribution among harmonics is also similar as shown
in Figs. 4(b) and 8(b). These parallels make the detection of 9-turn
4.1.3. 9-turns fault fault in no-load case a challenging task, which will be discussed
For 9-turn fault scenario, the NL acoustic data and its first com- below. Similar to the cases discussed above, unlike the NL case,
ponent show similar behavior as in the healthy case. This can be the 110 Hz component can be observed with a significant energy
observed by comparing Fig. 3(a) with 7(a). In both cases, similar content in full-load case.

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L.S. Maraaba, A.M. Memon, M.A. Abido et al. Applied Acoustics 173 (2021) 107661

Table 4 4.1.4. 26-turns fault


Frequency modes for FL operating mode in the 11th component of SSA. NL 26-turns fault’s acoustic signal shows resemblance with the
Mode – Fault Approx. Frequency [Hz] corresponding healthy and 9-turns fault cases such that a similar
Full load – Healthy 1900 envelop is followed. This is not true for NL 4-turn fault where a sig-
Full load – 4-turn fault 1400 nificant distortion is observed in the envelop (Fig. 5(a)) due to the
Full load – 9-turn fault 500 presence of 25 Hz component.
Full load – 26-turn fault 2450 Comparison of Fig. 9(a) with (b) depicts the acoustic signal fol-
Full load – 40-turn fault 1200
lowing an envelope for NL as opposed to its FL counterpart. The

Fig. 14. FFT of 11th component of FL acoustic data, samples ‘N’ = 96000, window length ‘L’ = 200. (a) Full-load 9-turn fault at 500 Hz. (b) Full-load 40-turn fault at 1200 Hz. (c)
Full-load 4-turn fault at 1400 Hz. (d) Full-load healthy at 1900 Hz. (e) Full-load 26-turn fault at 2450 Hz./.

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L.S. Maraaba, A.M. Memon, M.A. Abido et al. Applied Acoustics 173 (2021) 107661

110 Hz component for FL mode can be observed in Fig. 10, which is 5. Conclusion
responsible for introducing the distortions in the first component.
In this work, a smart phone was used to record the acoustic sig-
nals for detection of stator inter-turn fault in a 1.0-hp interior
4.1.5. 40-turns fault mount LSPMSM. Various fault levels were emulated under no
To demonstrate the effectiveness of the proposed SSA-based and full-load conditions. The acoustic signal for each case was ana-
algorithm, a more severe 40-turn shorted fault has been examined lyzed using SSA, which results in decomposition of the signal into
(see Fig. 11). It was observed that the NL and FL modes can still be the periodic components and noise. Fast Fourier Transform (FFT) of
differentiated using 110 Hz component for later, where the har- each component was then carried out to find the unique frequency
monics of 30 Hz can still be observed for former as shown in representative for each fault case.
Fig. 12(b). This shows the effectiveness of SSA to successfully iden- Following conclusions can be drawn from this work:
tify the no and full load cases. Unlike the previous cases, first com-
ponent for NL shows higher amplitude, comparable to that for the  Audio signals collected using the smart phone can be used for
FL case, while retaining nearly sinusoidal behavior as illustrated in the fault diagnosis of inter-turn faults in LSPMSMs.
Fig. 12(a). Furthermore, the first component for FL case has lesser  It is possible to differentiate, with high accuracy, between the
energy as compared with corresponding 4, 9, and 26 turn fault fault severities under no and full-load operation using SSA.
cases.  It was observed that the first component of SSA decomposition
characterized the loading condition by showing 30 Hz and its
4.2. Healthy and faulty conditions harmonics for no-load, and an additional 110 Hz component
for full-load.
After successfully identifying the load condition of the motor,  Distinct frequencies were observed for healthy and faulty con-
next obvious step would be to differentiate among different ditions in 18th SSA component for no-load, and 11th compo-
inter-turn faults based on their severity. The analysis using SSA nent for full-load operation.
algorithm was used with the same window length L ¼ 200 and
FFT of the first thirty out of 200 components was visually inspected CRediT authorship contribution statement
to find the distinct frequencies for each fault case as well as healthy
mode of operation. Multiple windows were analyzed for each data Luqman S. Maraaba: Conceptualization, Validation, Investiga-
set using the same window length of 200 samples. Specifically, tion, Data curation, Writing - original draft, Funding acquisition.
they were 0–53000, 45000–52000, 82500–90000, and 0–96000 Azhar M. Memon: Conceptualization, Software, Validation, Formal
samples, i.e., complete signal frame of 2 s. As described above, dif- analysis, Investigation, Writing - original draft, Visualization. M.A.
ferent windows have been examined to ensure that the analysis Abido: Data curation, Writing - review & editing, Supervision. Luai
algorithm does not depend on the window size and its placement M. AlHems: Writing - review & editing, Supervision.
over the complete data frame. Consistent results were observed for
each window despite the presence of different types of noise Declaration of Competing Interest
within given acoustic frame. In this paper, the results for only 0–
96000 window are shown to maintain brevity. NL scenario is dis- The authors declare that they have no known competing finan-
cussed below, followed by the FL case. cial interests or personal relationships that could have appeared
For the NL condition, 18th component shows distinct frequency to influence the work reported in this paper.
modes for healthy as well as each fault case. The approximate fre-
quency modes observed are shown in Table 3 and illustrated Acknowledgment
through Fig. 13. However, it was challenging for 9-turn fault to dif-
ferentiate between the frequency peaks as shown in Fig. 13(b) as The authors would like to acknowledge the support provided by
the peaks of 4-, 9-, and 40-turn faults can be observed around the Deanship of Research at King Fahd University of Petroleum &
2400 Hz. On the other hand, the 9-turn fault in NL operation is Minerals (KFUPM), Saudi Arabia for funding this work through Pro-
the only case where this peculiarity is observed and it can be tack- ject No. SR181028.
led using sophisticated peak-detection algorithms, which are sen-
sitive to minor frequency shifts. An alternative can be the use of References
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