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Machinery Fault Identification Using Blind Sound Separation and Fuzzy System
Machinery Fault Identification Using Blind Sound Separation and Fuzzy System
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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.
the analyzed sound signal. The fundamental frequency will 5, we includes those frequency into fuzzy rules. The the fuzzy
be used to characterize the sound pattern of machine sound. rules for machine fault identification are shown below.
Then, the fundamental frequency data can be used as input Fuzzy IF-THEN rules:
for fuzzy system to automatically determine the condition of
machine. • If F0 =32.53-69.67 and F1 =1757-1789 and F2 =2618-
Instantaneous frequency, which is defined as the derivative 2696 then the machine is NORMAL
of phase with respect of time, is a novel tool to estimate time- • If F0 =27.62-58.28 and F1 =995-1005 and F2 =1732-1808
varying parameter with high accuracy. Using the fact that the then the machine is UNBALANCE
instantaneous phase angle of the input sequence is the (un- • If F0 =21.31-67.62 and F1 =1764-1782 and F2 =2501-
wrapped) angle of the analytic signal, the instantaneous fre- 2697 then the machine is MISALIGNMENT
quency is the rate of change of the instantaneous phase angle • If F0 =22.17-117.24 and F1 =200.50-285.00 and F2 =
with respect to time. First, the derivation will depart from win- 303.90 - 379.80 then the machine is BEARING FAULT
dowed Fourier transform point of view to estimate the instan- The rules show that we used three frequency as input for
taneous frequency. By means of the notion of instantaneous fuzzy system. The implementation of the fuzzy system is to
frequency amplitude spectrum, then the harmonic structure of identify whether machine is normal, unbalance, misalignment
signal can be revealed to determine the fundamental frequency or bearing fault. Because we use instantaneous frequency ap-
[4]. This illustration on Fig. 3 show how to compute F0 based proach to estimate fundamental frequency so the frequency
on instantaneous frequency. The left figure is definition of is changed with respect to time. It resulted the fundamental
the instantaneous frequency amplitude spectrum (IFAS). The frequency has range as we used in fuzzy rules above. The us-
right figure shows an example of STFT (up) and its discrete ing of fuzzy system will make easier than direct analysis of
IFAS spectrum (down). As we can seen, the F0 based in IFAS instantaneous frequency to determine the machine condition.
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- 6 R ESULTS AND D ISCUSSION
tween two signal means that it is the estimated signal. The The data were recorded and digitized with a multichannel
value of F0 then was used to build fault identification using 24-bit audio ADC with 44.1kHz sampling frequency to avoid
fuzzy system. 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.
Fig. 3: F0 Estimation Based On Instantaneous Frequency [4] 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
5 P ROPOSED F UZZY I DENTIFICATION for unbalance condition is shown on Fig. 6.
S YSTEM On fig. 5(a), it can be seen clearly that on the normal
Before we design the Fuzzy identification system, first, condition the machine emits low frequency. The red color
we have identified some machine condition commonly occurs dominated in low frequency region and yellow in the upper
in industrial setting. We recorded the machine’s sounds with frequency region. In this case, the normal machine has av-
prior knowledge of the condition for validation and perfor- erage frequency at 51 Hz, between 1000-1300 Hz, 1770 Hz.
mance evaluation. The F0 data then used to build the fuzzy Fig 5(b) is spectrogram of unbalance machine. It shows that
identification as shown on Fig. 4. Due to the frequency of there are increment frequency around centre of the spectro-
machine is not single, but some frequency appears as in Fig. gram (more red color exists). The unbalance machine in this
Fig. 6: Comparison of Original and Estimated Signal For Unbalance Condi-
tion