Motor Fault Detection Using Sound Signature and Wavelet Transform
Motor Fault Detection Using Sound Signature and Wavelet Transform
Corresponding Author:
Emad Awada
Department of Electrical Engineering, Al-Balqa Applied University
Amman, Jordan
Email: emad.awada@bau.edu.jo
1. INTRODUCTION
In today's large and heavy industries revolution, induction motors play an important role as driver
machinery due to their affordable cost, easy maintenance, high reliability, and ease of operations. However,
this is not the case all the time, since many faults may occur causing failures or even breakdown with potentially
catastrophic results. Many of these faults are indistinguishable, can't be detected, and could inherent into the
machine main core causing bigger issues. Therefore, faults such as broken rotor bars, winding faults, bearing
failure, stator, and rotor unbalanced, and many more other faults needs to be detected and identified [1], [2].
Meanwhile, as an economic value, voltage distortion and phase imbalance costs the US somewhere between 1
to 2 billion dollars a year in failures [3].
Many researches have been done to develop a processing system of monitoring, collecting, and
analyzing data required to prevent major failures. In fact, undetected small failures could potentially lead to
catastrophic failures with consequences of extreme vibrations, poor performances, and high thermal stress [4],
[5]. A variety of machine faults detection applications were studied by many researchers [4]−[9] to determine
and diagnose faulty incidents through waveform spectral components such as voltage, current, power,
temperature, vibrations, and sound captured during the brief operation. In most researches, digital signal
processing (DSP) has been used as primary tools in the area of electrical machines faults detection analysis and
advanced over the recent decades [8]−[11]. However, such detection is based on conventional DSP analysis of
Fourier transform [7].
Although Fourier transform has wide usage in DSP applications, Fourier transform analysis has some
shortcomings comparing to other analysis algorithms [12]. For example, in Fourier, a transformed signal from
time to frequency domain may losses some critical data information. In addition, Fourier has shown a lack of
ability for non-stationary signals analyzing [12], [13], as Fourier transform assumes individuality of each
frequency component, gives a limitation approach.
Other researches, as in [14]−[17], have been invested in presenting their tested waveform data in
methods of time-varying or nonstationary based on dilation and translation of a signal to provide dynamic time
and frequency localization adjustable windows (scaling concept to fit multi-frequency components). However,
in this work, a unique special feature of the wavelet transform algorithm will be used to deliver a combined
framework for advanced signals processing analysis application with much fewer data samples and shorter
testing time [18], [19] for stationary and non-stationary motor output sounds waveform.
As a result, discrete wavelet transform (DWT) will be presented as a new method of detecting machine
failure based on faulty noise indication to identify fault potential that may lead to machine malfunctions. The
distinctive of this new proposed DWT algorithm will allow analyzing machine output sounds with fewer data
samples as compared to fast Fourier transform (FFT) by the unique property of decomposition and de-noising
filters to isolate faulty frequencies and locate abnormality faster and in early stages.
With frequency component 𝜔 in the 𝑗-th element of 𝑥𝑜𝑢𝑡 (ℎ), Parseval's theorem for FFT [19], the estimation
of the variance of the signal 𝑠(𝑛) (which is also the signal power ps ) as given in (3).
2
𝑝̑𝑠 = |𝑥(𝑗)|2 (3)
(𝜇−1)𝜇
2
𝑝̑𝑛 = ∑(𝜇−1)/2
ℎ=1
|𝑥(ℎ)|2 𝑎𝑛𝑑 ℎ≠𝑗 (4)
(𝜇−1)𝜇
As a result, the combination of both (3) and (4) yields SNR for frequency 𝜔 as in (5).
|𝑥(𝑗)|2
𝑆𝑁𝑅 = 10log10 [ (𝜇−1)/2 ] 𝑎𝑛𝑑 ℎ ≠ 𝑗 (5)
∑ℎ=1 𝑥(ℎ) 2
3. WAVELET TRANSFORM
While Fourier transform signal analysis is done based on one window analysis fit all frequencies,
wavelet transforms provide an adjustable window analysis for different frequencies to provide good resolution
in the time domain for a high-frequency component of the signal and good resolution in frequency for
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Int J Pow Elec & Dri Syst ISSN: 2088-8694 249
low-frequency component of the signal [22], [23]. As a result, an automatic analysis window of wavelet
transform is done through the shifting and scaling process based on mother wavelet form [5]. In continuous
wavelet transform, the original signal multiplied by scaling and shifting algorithm of a wavelet to be summed
over time and produces low-pass and hi-pass coefficients as in (6).
∞
𝛹𝑎,𝑏 (𝑡) = ∫−∞ 𝑓(𝑡) 𝜙𝑎,𝑏 (𝑡)𝑑𝑡 (6)
Where
1 𝑡−𝑏
𝜙𝑎,𝑏 (𝑡) = 𝜙 𝑎𝑛𝑑 𝑎 > 0
√𝑎 𝑎
Where:
𝑥[𝑛]is discrete signal
𝜙𝑗𝑜,𝑘 [𝑛] is scaling function
𝜑𝑗,𝑘 [𝑛] mother wavelet at scaling function
𝑎𝑗𝑜,𝑘 approximation coefficients at scaling function
𝑑𝑗,𝑘 detail coefficients at scaling function
By applying DWT filter bank of high-pass and low-pass algorithms, detail coefficients are passed
through the high-pass filter h[n] and approximation coefficients are transferred through a low-pass filter g[n]
followed by a down-sampling by two driven by mother wavelet and the scaling function [20], [21], [28], as
shown in Figure 1, which makes DWT suitable for signal analysis with fewer data samples and particularly for
transient signals. However, in this work, instantaneous amplitude measurements and waveform dynamic range
will be based on the low-pass approximation coefficients to eliminate noises and obtain an accurate reading.
S with N data
points
Low pass
filter cA low
frequency with
Down sampling N/2 data coeff.
Motor fault detection using sound signature and wavelet transform (Emad Awada)
250 ISSN: 2088-8694
Stator Rotor
Winding Winding
Bearing
Fault detection and condition monitoring of induction motor can be performed in many techniques
such as sound signature analysis, vibration analysis, acoustic emission analysis, motor current signature
analysis, temperature monitoring, and many other techniques [9], [17], [30]. In this work, sound signature
analysis will be used to define any potential failure or potential error that may lead to a failure. As it's known,
the sound is mechanical wave vibration of a medium (solid, gas, liquid) that propagate and transfer at pressure
rate change known as frequency, and the differences among the level of pressure characterize amplitude.
By converting such pressure and amplitude into electrical signals, a discrete wavelet decomposition
process can be applied in two levels to obtain approximation coefficients data. For example, using Haar wavelet
decomposition process for the first level as in (8) if the digitized signal assumed to be z(n).
2 2 2
z (1)
2 2 2
2 2 2
− − (1)
2 2 2
2 2 2
• z ( n) = z (2) (8)
2 2 2
2 2 2
− − z (2)
2 2 2
1
2
2
z (1)
2 2
2 2 2
−
(1)
2
2 2
− (9)
2 2 • 2
2
z (2)
2 2
2 2 − 2 z (2)
2 2 2
−
2 2
As a result, detection of sound changes can be determined through waveform amplitude voltage
change and dynamic range increases (ratio of the largest and smallest component of a signal that can be
measured expressed in dB [21]). DR can be given by (10).
As mechanical faults such as bearing faults or unbalance faults, or electrical faults such as stator or rotor
winding faults may occur, unique sound changes in frequency amplitude can be defined by the frequency
spectrum, which indicates a faulty or potential fault operation. However, in this work, due to the large number of
samples collected and processed by FFT to obtain frequency spectrum, wavelet decomposition will be used to
decrease the number of processed and stored data samples [12], [18], [24]. As shown in Figure 3 (flowchart), a
continuous monitoring sequence and data acquisition as iterative MATLAB code will be performed on induction
motor to collect sounds waveform data samples, apply DWT filtration and amplification to eliminate noise and
analyze for abnormality.
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Initialize Induction
Machine Data equisition
Compute error
No Abnormality
Error<Tolerance
Wave-sound
Yes
Normal Alert
Operation
Output
Results DR
Output
Motor
In this work, a clean consistent sinusoidal waveform has been simulated as motor sound without
additive error is ordered to implement a conventional testing analysis of FFT and new wavelet transform
analysis. The test was intended to show the abilities of both FFT and DWT testing analysis in processing,
de-noising, and explores waveform data. As noticed in Figure 5, the FFT power spectrum has specified the
fundamental frequency without data decomposition or showing any other critical waveform components.
While, in Figure 6, DWT has performed a de-noising and decomposition process to reveal data components of
waveform characteristics in terms of amplitude and dynamic range changes.
Meanwhile, by adding abnormality to the fundamental signal as a source of potential motor failure,
the new output sound waveform was analyzed and the process by both testing algorithms to define the
amplitude and standpoint of the potential failure. In Figures 7 and 8, as it shows the noisy output motor sound,
the FFT algorithm was used to obtain the power spectrum and define unwanted data attached to the waveform.
However, it was noticed that the noises component was closer to the noise floor and the amplitude of
fundamental frequency was very high to define the magnitude of amplitude changes or any significant dynamic
Motor fault detection using sound signature and wavelet transform (Emad Awada)
252 ISSN: 2088-8694
range alteration. Meanwhile, in Figure 9, the same output waveform was analyzed by DWT to perform a de-
noising and decomposition process. In this algorithm, DWT was able to pinpoint and represent changes
(distortion) that occur within the waveform with one-fourth number of data samples. That is, the amplitude
change was clearly defined and dynamic range alteration was determined based on the changes of the highest
and lowest waveform amplitude of the approximation decomposition cA with much fewer data samples and
time to compile.
Figure 5. Original clean waveform and power Figure 6. Original clean waveform and discrete.
representation of frequency domain wavelet analysis
Figure 7. Faulty waveform and power spectrum Figure 8. Original faulty waveform and power
representation of frequency domain spectrum representation of frequency domain
By obtaining the maximum and the minimum deconstruct waveform amplitude, the dynamic range
was computed based on different types of mother wavelet. For a clean motor waveform with no failure,
Tables 1 and 2 show the instantaneous dynamic range of normal operation for both no-load and with load
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status. Meanwhile, Tables 3 and 4 show an instantaneous dynamic range for faulty waveform for both no-load
and with load respectively.
This test was based on two different algorithms. For FFT, signal to noise ratio was used to determine
the level of noise due to failure occurrence measured in dB. Meanwhile, wavelet transforms algorithms were
used based on waveform dynamic range calculation to determine failure occurrence. Based on results shown
in Tables 1 to 4 and Figures 10 (a) and 10 (b), it was clear that wavelet transforms algorithms significant
results by using Daubechies (dbn) wavelet at the second level of waveform decomposition
(a) (b)
Figure 10. Motor failure detection based on dynamic range calculation for (a) instantaneous DR measurement
at 1st level decomposition and (b) instantaneous DR measurement at 2nd level decomposition
6. CONCLUSION
In this work, the properties of DWT decomposition and de-noising were implemented as advanced
signal processing techniques to monitor the behavior of electrical motor. Fault diagnosis of induction motors
was based on the algorithms of Fourier transformations for SNR fault indication technique and wavelet
transform for DR indications where used. Hence, even though the two techniques were different in compiling
samples method and testing result, DWT has shown promising results in detecting faulty sounds with mush
less data to compile. That is, by comparing results in terms of number of collected data samples, Fourier
transformation did not show sufficient results in term of SNR (due to large number of collected data sample in
power spectrum), while, wavelet transform had shown promising results in terms of computing DR and spotting
deviation of motor error. In addition, based on wavelet decomposition coeffients, Daubechies wavelet has
shown superior results in term of motor error detection in both 1st and 2nd level decomposition.
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BIOGRAPHIES OF AUTHORS
Int J Pow Elec & Dri Syst, Vol. 13, No. 1, March 2022: 247-255
Int J Pow Elec & Dri Syst ISSN: 2088-8694 255
Eyad Radwan completed his BSc. from JUST in 1996, MSc. and PhD. from
UPM (Malaysia) in 1999 and 2004 respectively. From 1999 till 2011 he was with UCSI
University and served as the Dean of the faculty of Engineering & built environment from
2007 to 2009, and as Chief Operating Officer from 2009 to 2011. He joined the dept. of
Electrical Engineering at the Applied Science Private University, Jordan in 2012. His
specialization is in the area of Electrical power, Drives and Control. He can be contacted at
email: e_redwan@asu.edu.jo.
Motor fault detection using sound signature and wavelet transform (Emad Awada)