Predictive Maintenance of Induction Motor using AI/ML

Juhi Singh, Akansha Sharma, Avinash Yadav, Utkarsh Singh

Department of Electrical and Electronics Engineering
ABES Engineering College, Ghaziabad

Abstract

The advancement in the industry facilitating manufacturing of products is leading to use of sensors to a great extent.
Utilization of manufacturing products without keeping the frequent maintenance might lead to a huge production loss.
With the advancements,predictive maintenance is benefited with real-time detection and prediction about future failures
with the help of AI and ML. Using AI and ML, conditioned monitoring of the machine is done and hence the regular
recorded data is compared on daily basis and any major calibration in the data predicts the maintenance. In the past years,
there is an increase in interest regarding advanced prediction about maintenance. In this paper, a survey is presented on
real- time AI/ML based predictive maintenance in the industry.

Keywords: Predictive Maintenance, Real-time Detection,

1. Introduction The basic idea of Predictive maintenance is that

Maintenance is the one of the most dominating factor
while deciding the cost to be invested in the industry.
Maintenance activities mainly originates the cost of the
most of the industries. Majority of the industries still
work on the policy of outdated maintenance and keeps
on producing until any major fault occurs or until the
scheduled time of maintenance arrives. This working
strategy of industries might lead to a big failure of
machinery and hence, a huge production loss. And
hence, resulting in lower product quality and lesser
time of production because of inappropriate policies of
maintenance.
According to some surveys on maintenance, it has been
seen that in US, some of dollar spent for maintenance
is wasted due to unnecessary or irregular maintenance
activity.[1] Also, many research regarding modern
policy of maintenance is done using various advanced
technologies in the different area of academics like
artificial maintenance, production, etc.
Using of advanced sensors and well-developed
techniques helps predict the life of the machinery in
industries hence, increasing the chances of increased
life-cycle of the machinery. This predictive
maintenance policy is much concerned for the
emerging advanced industries and hence contributes in
enhancing the efficient modern production facility.[1]
monitoring of some characteristics of machines is
possible and the data collected can be used to estimate
the life-cycle of the machinery. Also, the policy of
predictive maintenance results in various
improvements in maintenance and manufacturing
process, reducing the cost of production. Predictive
maintenance, at first, reduces a lot of unnecessary
maintenance activity that are not based on maintenance
at every specific period till its life-time.And hence,
reduces the total times maintenance is to be done for
the machine. Also, this helps in avoiding the too early
maintenance activity as well as too late maintenance as
the machine may fail much as the maintenance periods
depends on the life-cycle that includes both negative
and positive difference from average mean.[2] AI
approaches have been extensively employed to derive
relevant information from manufacturing data. By
employing previous experience gained via training, the
strategies give the systems intelligence to learn from
and get used to the day to day modifications in the
environment. These skills allow manufacturers to
predict the subject of their interest.[2]
Application of AI algorithms to the production
model can therefore roughly predict how it will behave
in the future, and the knowledge so produced may aid
in decision-making.
 Figure 1: Maintenance Policies

upgraded and statistically planned predictive

1.1. Structure of paper maintenance programme with a respectable residual
life prediction model achieves a higher average
The format of this research paper is: Section 2 availability[3].
describes Literature Review for predictive In 2001, For all the important machinery of a
maintenance. Section 3 describes the framework power plant, recurrent neural network approach was
design. The project's methodology and working created, tested, and ran. The outcomes demonstrated
method are explained in Section 4. Result and that the IPDSS model offered trustworthy fault
discussion and different tools and software used are diagnostics & excellent equipment deterioration trend
also included in section 4. Section 5 includes results prediction power.
and Section 6 shows the conclusions. Section 7
provides a list of the sources consulted for the research
report.
3. Framework for Predictive Maintenance
There are 10 categories in all in the predictive
maintenance framework. The ten categories, which
2. Literature Review represent the framework's top level, are shown in
Figure 2.
Numerous studies on predictive maintenance have
been conducted throughout the years, and hundreds of
new papers are currently being published every year.
In 2019, the motor specifically spindle one and
cutting tool were two crucial components of the
machine tool system that the AI-based predictive
maintenance algorithms were used to monitor.[3] As a
result, it was possible to efficiently monitor the
environment and determine how quickly the tools
were degrading.
In 2018, The suggested policy's performance was
compared to the performance of the traditional Figure 2: Predictive Maintenance Framework categories
statistical lifespan distribution-based policy. The
comparison results demonstrated that the individually
2
 3.1. Goals
Typically, the category of aims is used to explain
the motivation behind selecting the topic of predictive
maintenance. Eight objectives have been selected for
our project: Reduce Spare Part Inventory, Extend
Machine Life, Reduce Costs, Reduce Downtime,
Availability, Productivity, Reliability, and Safety.
Figure 3 displays all characteristics that fall under the aims category
An effective predictive maintenance system would
make it possible to just store the spare parts that will
likely be needed soon rather than all possible spare
components.[4] Consequently, the predictive
maintenance system would decrease the need for spare
components to be kept on hand.
3.2. Condition Monitoring
The basis of a predictive maintenance strategy is the
data collection from a machine/component that reveals
its state of health and enables the estimation of the
remaining usable life on the basis of output data.
Inspection-Based Monitoring, Sensor-Based
Monitoring, Continuous Monitoring, and Online/Real
Monitoring are the four different features that make up
the condition monitoring category. Figure 4 displays
each characteristic along with the frequency at which it
occurs.
Figure 4: Condition Monitoring
Data is only gathered during inspection intervals with
inspection-based monitoring. Contrary to normal
policies of maintenance, the intervals are not fixed.
Sensor-based monitoring uses a variety of sensors to
3
gather the necessary data, such as those that monitor
temperature and vibration.[5] Keep in mind that
inspection-based monitoring and sensor-based
monitoring are not mutually exclusive given that sensor
equipment is frequently required for performing the
inspection.
3.3. Maintenance Scope
For those situations where the scope of maintenance is
not expressly indicated, the current study makes no
assumptions regarding it. The three distinct features for
the category maintenance scope were revealed by the
study of the articles. Figure 5 displays all characteristics
falling under the maintenance scope group.
Figure 5 shows the Category Maintenance Scope in general.
The premise behind the attribute of flawless
maintenance is that any maintenance procedure
performed on a machine or component would return its
functionality and durability to where they were before.
Consequently, let's look at a fresh machine's state [6].
3.4. Degradation Process
Deterioration modelling is the technique of
determining how quickly a machine or component will
deteriorate based on pertinent machine health
indication data, such as temperature or vibration [6].
The purpose of this process is to acquire data regarding
a certain machine's typical condition all along duration
of its life cycle. The modelling of the degradation
process is advantageous in that understanding a
machine's pattern of faults can help a predictive
maintenance system more accurately identify
upcoming breakdowns.
3.5. Fault Detection
To schedule maintenance activities in a suitable
manner and scope, a pure predictive maintenance
strategy primarily focuses on the forecasting of the
machinery and components’ future. Based on the data
gathered, it attempts to pinpoint the primary reason for
the failure. Diagnostics' additional purpose is covered
by fault detection. Therefore, both machinery
diagnostics and root cause analysis target the same
problem. The majority of researchers use the term
 "machinery diagnostics," while some also use the word
"root cause analysis" or both meanings.
3.6. Scheduling
With the use of a predictive maintenance method,
maintenance tasks can be efficiently scheduled by
identifying their time and requirement in advance.
The ability to dynamically modify the maintenance
schedule in response to fresh and processed condition
monitoring data is referred to as dynamic action
scheduling. In addition to the maintenance tasks
themselves, the predictive maintenance system is
linked to the necessary spare part ordering, which
results in dynamic spare part availability [7].
Compared to an isolated strategy, this approach is more
comprehensive and matches the modern concept of
Industry 4.0 and the smart factory.
3.7. Prognostic Techniques
One of the most important categories for predictive
maintenance is prognostic approaches, even though all
monitoring and data collecting are essential.[7] Keep in
mind that the information given by a prognostic
technique is merely a probability because it aims to
forecast a potential breakdown of a machine or
component. Three characteristics were discovered for
the category of prognostic strategies for the predictive
maintenance framework of the current survey.
It is crucial to keep in mind that all of these prognostic
methods depend on monitoring data to make their
forecasts. Therefore, all of these strategies are in some
sense data-driven.
3.8. Data Handling
The category data handling is concerned with the
volume of data that condition monitoring generates.
Particularly in situations of continuous monitoring with
several sensors, and the data acquired by these sensors
ends up in a considerable volume of data that must be
processed. Data Access, Data Fusion, Data Filtering,
and Storage Location are all crucial features.[8] The
secondary features of local and distant/cloud data
storage, as well as local and remote data access, are
divided under the primary characteristics of storage
location and data access.
4. Methodology
4.1. Working Principle
In order to use maintenance sensor, workers must first
install and set up the sensor model interface on the
4
machinery, such as a smart oven or assembly line.
• Monitoring sensor, either in-person at the concerned
sensor unit or remotely via a gadget.
• Making decisions in accordance with the sensor's
instructions and keeping the sensor updated as
necessary.
The main working principle is that the chosen Gyro
Sensor will sense any change in the position or if there is
any motion than the normal. These will be used to detect
any fault as it’ll show that there is a huge vibration
occurring inside the machine and hence maintenance can
be done in time saving the machine and increasing its
life.
4.2. Component details
The operation of the system is controlled by the sensor
named as Gyro sensor.
• By initially setting up the sensor on the equipment,
such as a smart oven or manufacturing line, and
installing them.
• Monitoring sensor, either in-person at the relevant
sensor unit or remotely via a device.
• Performing any necessary maintenance on the sensor.
• Making decisions when the sensor indicate that doing
so is necessary.
Based on these measurements, we will monitor the
induction motor and look for issues. We reviewed the
datasheets of many sensors to find the one that was most
suitable for the project and selected MPU6050 as Gyro
Sensor.
This sensor was now connected to an Raspberry Pi,
to which code was uploaded using the Visual
Studio Code, in order to monitor and output data.
4.2.1. 0.96inch OLED DISPLAY
Figure 6: 0.96inch OLED Display
A 0.96-inch, 128X64 high-resolution display is
incorporated within the OLED 0.96-inch monochrome
graphic display module. Even without lighting, OLED
0.96inch can operate. LCD displays have lesser contrast
in comparison to OLED displays in the case of dark
room. They are thinner than LCD screens, have high
brightness, and create more accurate and vibrant colour.
When powered by a DC 2.8V source, the 0.9inch OLED
Display Module generates blue lettering on a black
backdrop with excellent contrast.
4.2.2. MPU6050 (GYRO SENSOR):
Figure 8: RP 2040
RP2040 is a microcontroller of high performance with
low cost. It is a 32-bit microcontroller. Large on-chip
memory, a symmetric dual-core CPU complex, a
deterministic bus fabric, and a comprehensive peripheral
set are all features of the Raspberry Pi RP2040
Microcontroller Chips. These chips also have thorough
documentation, a well-executed MicroPython port, and a
UF2 boot-loader in ROM. They are enhanced with a
special programmable I/O (PIO) subsystem for power
and flexibility. The affordable modules are made to
provide excellent performance and simplicity of usage.
Stateless hardware.

Its peripherals are-:

 No. Of UARTs: 2
Figure 7: MPU6050  No. of SPI controllers: 2
 No. of I²C controllers: 2
 Scale factor  16 PWM output channels
 Temperature-frequency coefficient  30 GPIO pins
 Compact size  2 PLLs
 Shock resistance  Controller of USB 1.1
 Stability and noise characteristics
MPU 6050 is a device that tracks motion in different 4.4. Software used:
dimensions. It is a device that tracks motion while
working on very low power with very low cost and for 4.4.1. EDGE IMPULSE:
the requirement for high maintenance devices. It
measures the orientation, displacement, acceleration and
other features that are motion related. It is mostly used
for its ability of position detection and control.

4.3. Tools Used

When it comes to computers,a controller is a

hardware/software that mainly works upon setting the
flow of data between two specific entity. Computer
controllers, which are independent pieces of hardware
used to operate peripheral devices, can be cards,
microchips, or other types of hardware. Any entity or Figure 9: Work Cycle of Edge Impulse
person who handles communication and serves as the
interface between two systems can be thought of as a Edge Impulse is the top platform for machine learning
controller. development on edge devices. It is open source and
relied upon by businesses all over the world. The
RP 2040 (RASPBERRY PI): business focuses on the application of sensor, audio, and
computer vision and experience for machine learning on
the edge to every developer and device maker. Edge
Impulse enables optimal efficiency and speed on a
variety of hardware.
Features of Edge Impulse:-
1. Data Acquisition
2. Impulse Design
3. Retrain Model
4. Live Classification
5. Model Testing
6. Deployment

5

Figure 10: Image of Data Acquisition
4.4.2. VISUAL STUDIO CODE:
Using the Electron Framework, Microsoft produced the
source-code editor Visual Studio Code, often known as
VS Code, for Linux, Windows, and macOS. Users may
modify the theme, keyboard shortcuts, settings, and add
functionality by installing extensions.
4.5. Steps involved:
 At first, appropriate sensor is selected and then
selection of appropriate microcontroller in order to
interface the sensor is done, followed by selection
of appropriate tools and software required to
complete the interfacing and model making is
done.
 The Gyro sensor(MPU6050) is interfaced with help
of Raspberry Pi(RP 2040) and its working
condition is then checked.
 Visual Studio Code is used to do the coding for the
Gyro sensor so that its working can be done by
implementing the codes to them with the help of
Raspberry Pi.
 The Edge Impulse collects the sensor’s data when
the code is implemented and gives various graphs
regarding its working.
 The Edge Impulse then provides a code which is
the actual and appropriate code for making the
Gyrosensor work properly.
 An 0.96inch OLED display is installed and
interfaced with the model using Raspberry Pi to
display the results of Gyro sensor.
5. Result
On moving the prepared project model even with a very
small unit i.e., in mm, the OLED display showed the
position change for such small change and the data was
used to relate the difference from the original position to
the latest position. This visualization of even such small
change can be used to predict motion based fault and
hence predictive maintenance is possible using this
methodology.
6. Conclusion
 The motion of the motor/machine can be judged
for its positional variation.
 Using ML, a data can be created regarding these
poitional variation.
 These dataset can be used to predict the working of
the machine.
 Any unusual change can be monitored for the
machine working.
 And hence, Predictive Maintenance is possible and
is very useful and have a growing industry in the
future.
7. References
[1] F. Liu, W. Wang, M. Y. You, G. Meng, Statistically
planned and individually improved predictive
maintenance management for continuously monitored
degrading systems, IEEE Transactions on Reliability 59
(4) (2010) 744–753. doi:10.1109/TR. 2010.2085572.
[2] R. K. Mobley, An introduction to predictive
maintenanc (2002) 1–6.
[3] Levrat, E., lung, B., Crespo Marquez, A.: E-
Maintenance: review and conceptual framework.
Production Planning & Control, 19(4), 408-429 (2008).
[4] Wu, H., Yun, H., Kim, Lee, W. J., H., Jun, M. B.,
using artificial intelligence techniques applied to
machine condition data. Procedia Cirp, 80, 506-511.
[5] X. Zhou, L. Xi, J. Lee, Reliability-centered
predictive main- tenance scheduling for a continuously
monitored system sub- ject to degradation, Reliability
Engineering and System Safety 92 (4) (2007)
[6] N. Akturk, V. Celik,S. Orhan, Vibration
monitoring: Comprehensive case studies, NDT&E
International 39 (4) (2006) 293–298.
doi:10.1016/j.ndteint.2005.08. 008.
[7] Thermal Imaging Technology for Predictive
Maintenance of Electrical Installation in Manufacturing
Plant- Shilpa Sambhi, ABES Engineering College
[8] Crosby, M, Nachiappan, Pattanayak, P., Verma, S.,
Kalyanaraman, V., 2016. BlockChain Technology:
Beyond Bitcoin. Applied Innovation Review, Issue No.
2 June 2016.