Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Machine Fault Analysis”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Rotor Magnet Fault Analysis in Permanent Magnet AC Machines Under Load Conditions - All Electric Transportation Systems

This paper studies the performance of a Permanent Magnet (PM) alternating-current (AC) machine when subjected to faults under load conditions. The effect of varying load torques, and unbalances are found to be potential causes of rotor faults, inducing physical magnet defects or broken rotor-PMs. The consequent and immediate impact on the machine quantities is observed through anomalous change in torque-speed characteristics and other vital signatures such as machine back-EMF/flux and motor current signatures (MCS). The present research study develops and illustrates a method to diagnose physical magnet defects (fault) in PMAC machines by estimating the machine torque/back-EMF constant, Ke. The constant Ke is a measure of magnet strength exhibiting the health of rotor PMs, indicative of faults. Advanced research studies and investigations are carried out to establish motor approximations and signature-based analysis as significant viable tools for diagnosing machine faults even under load conditions.

alternating current↗
DOE OSTI2023

Integrating Survival Analysis with Bayesian Statistics to Forecast the Remaining Useful Life of a Centrifugal Pump Conditional to Multiple Fault Types

To improve the viability of nuclear power plants, there is a need to reduce their operational costs. Operational costs account for a significant portion of a plant’s yearly budget, due to their scheduled-based maintenance approach. In order to reduce these costs, proactive methods are required that estimate and forecast the state of a machine in real time to optimize maintenance schedules. In this research, we use Bayesian networks to develop a framework that can forecast the remaining useful life of a centrifugal pump. To do so, we integrate survival analysis with Bayesian statistics to forecast the health of the pump conditional to its current state. We complete our research by successfully using the Bayesian network on a case study. This solution provides an informed probabilistic viewpoint of the pumping system for the purpose of predictive maintenance.

42 ENGINEERING↗
DOE OSTI2021

Deep Cellular Recurrent Network for Efficient Analysis of Time-Series Data With Spatial Information

Efficient processing of large-scale time series data is an intricate problem in machine learning. Conventional sensor signal processing pipelines with hand engineered feature extraction often involve huge computational cost with high dimensional data. Deep recurrent neural networks have shown promise in automated feature learning for improved time-series processing. However, generic deep recurrent models grow in scale and depth with increased complexity of the data. This is particularly challenging in presence of high dimensional data with temporal and spatial characteristics. Consequently, this work proposes a novel deep cellular recurrent neural network (DCRNN) architecture to efficiently process complex multi-dimensional time series data with spatial information. Here, the cellular recurrent architecture in the proposed model allows for location-aware synchronous processing of time series data from spatially distributed sensor signal sources. Extensive trainable parameter sharing due to cellularity in the proposed architecture ensures efficiency in the use of recurrent processing units with high-dimensional inputs. This study also investigates the versatility of the proposed DCRNN model for classification of multi-class time series data from different application domains. Consequently, the proposed DCRNN architecture is evaluated using two time-series datasets: a multichannel scalp EEG dataset for seizure detection, and a machine fault detection dataset obtained in-house. The results suggest that the proposed architecture achieves state-of-the-art performance while utilizing substantially less trainable parameters when compared to comparable methods in the literature.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Use of Machine Learning on PMU Data for Transmission System Fault Analysis

Synchrophasor technology has been used for monitoring, control, and protection of bulk power system for over 10 years. Deployment of phasor measurement units (PMUs) in the USA power system has surpassed 3000 units installed in the transmission substations as stand-alone intelligent electronic devices (IEDs) or as a software add-on to other devices such as digital protective relays (DPRs) or digital fault recorders (DFRs). By now, thousands of terabytes of PMU data may have been captured and stored by various transmission system operators (TSOs) and independent system operators (ISOs). This creates an opportunity to deploy advanced machine learning (ML) techniques to detect and classify faults recorded by PMUs automatically to be used by the system operators for rapid, critical decision-making when manual analysis of the past or unfolding events is not feasible. In this paper we offer a brief background on how the automated fault analysis may be done using DPR and/or DFR data, and compare some of the legacy approaches to the new ML approaches in the context of the system-wide PMU recordings. We then offer insights from developing practical ML solutions that have been applied on field recordings captured by close to 450 PMUs from all three US interconnections (Western, Eastern and ERCOT) over two years (2016-2017). We identify and illustrate ML challenges we addressed: inaccurate data, data with scarce and temporally imprecise fault labels, data recorded by PMUs sparsely located at substations resulting in the fault records taken afar from the ends of the faulted lines, data containing only positive sequence values, and data taken at different voltage levels. We then illustrate the ML model results for fault analysis under different application scenarios. The novelty of this study is not only in the design, implementation, and performance analysis of the ML algorithms, but also in the use of advanced fault modelling and simulation approaches to improve the training results when developing supervised ML models for fault detection and classification. Extensive simulations of faults were conducted on a 14-bus power system to create a training dataset with over 1400 accurately labelled faults. This dataset was applied to enhance the accuracy of fault detection and classification of machine learning-based models trained with small number of labelled faults in large datasets recorded in the grid interconnections ranging from 5,000 to 70,000 buses.

Synchrophasors, Machine Learning, Fault Analysis, ↗
DOE OSTI2022

ARETE: Accurate Error Assessment via Machine Learning-Guided Dynamic-Timing Analysis

Nanometer circuits are increasingly prone to timing errors, escalating the need for fault injection frameworks to accurately evaluate their impact on applications. Here in this paper, we propose ARETE, a novel cross-layer, fault-injection framework that combines dynamic-binary instrumentation with machine learning-guided dynamic-timing analysis. ARETE enables accurate fault-injection into any application by estimating the location of the injecting errors via dynamic-timing analysis. To accelerate fault-injection, we develop a novel, data-aware, machine learning-based mechanism that dynamically pre-selects the error-prone instructions and limits the application of the costly dynamic-timing analysis only to them. To evaluate ARETE's accuracy, our fully automated toolflow is configured to support fault-injection based on detailed post-layout gate-level simulations as well as via existing workload-agnostic error models. Our results for various workloads, including an autonomous-driving library, show that the location and time of injected errors performed by ARETE, is 89.9% consistent with fault-injection based on full gate-level simulation. On average, ARETE executes 84.6x faster than gate-level simulation and at a cost of 3.4% loss in the program output quality estimation. When compared to the existing statistical fault-injection tools that are based on workload-agnostic error models, ARETE improves the accuracy of fault-injection rate and output quality estimation by 143.9% and 40.4% on average, respectively.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Ensemble models for circuit topology estimation, fault detection and classification in distribution systems

This paper presents a methodology for simultaneous fault detection, classification, and topology estimation for adaptive protection of distribution systems. The methodology estimates the probability of the occurrence of each one of these events by using a hybrid structure that combines three sub-systems, a convolutional neural network for topology estimation, a fault detection based on predictive residual analysis, and a standard support vector machine with probabilistic output for fault classification. The input to all these sub-systems is the local voltage and current measurements. A convolutional neural network uses these local measurements in the form of sequential data to extract features and estimate the topology conditions. The fault detector is constructed with a Bayesian stage (a multitask Gaussian process) that computes a predictive distribution (assumed to be Gaussian) of the residuals using the input. Since the distribution is known, these residuals can be transformed into a Standard distribution, whose values are then introduced into a one-class support vector machine. The structure allows using a one-class support vector machine without parameter cross-validation, so the fault detector is fully unsupervised. Finally, a support vector machine uses the input to perform the classification of the fault types. All three sub-systems can work in a parallel setup for both performance and computation efficiency. In conclusion, we test all three sub-systems included in the structure on a modified IEEE123 bus system, and we compare and evaluate the results with standard approaches.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Smart connected worker edge platform for smart manufacturing: Part 2—Implementation and on‐site deployment case study

Abstract In this paper, we describe specific deployments of the Smart Connected Worker (SCW) Edge Platform for Smart Manufacturing through implementation of four instructive real‐world use cases that illustrate the role of people in a Smart Manufacturing paradigm through which affordable, scalable, accessible, and portable (ASAP) information technology (IT) acquires and contextualizes data into information for transmission to operation technologies (OT). For case one, the platform captures the relationships between energy consumption and human workflows for improved energy productivity while workers interact with machines during semiconductor manufacturing. The platform utilizes human cognition to identify anomalous machine behavior for root cause analysis of system faults via neural network (NN) that recognize alarm postures of workers with cameras. For case two, a smart assembly line is demonstrated for state monitoring and fault detection. Machine learning (ML) models are used to recognize system states and identify fault scenarios with human intervention. For case three, the platform monitors human–machine interactions to classify manufacturing machine states for proper operations and energy productivity. Internal energy states of individual or collections of manufacturing equipment are determined via NN based algorithms that disaggregate signals associated with smart metering typically deployed at manufacturing facilities. These methods predict the real time energy profile of each machine from the total energy profile of a manufacturing site. For case four, a software defined sensor system built with scientific workflow engines is demonstrated for contextualizing data from laser surface refraction for characterization, and diagnostics in the processing of additively manufactured titanium alloy.

Donovan, Richard P.↗
DOE OSTI2020

Research Introduction [Slides]

In the topic of Reverse Time Imaging, we proposed a new IC to reduce computation cost but reserve image resolution for distributed sensor networks. For Induced Seismicity in Oklahoma, we analyzed fault stress state analysis at state scale, and we applied machine learning techniques to polarity picking and seismicity rate forecasting. The results provide better understanding of fault properties, stress field, and the relationships among fault, stress state, injections, and potential seismic hazards. Lastly, for Microseismic Monitoring, we detected and located 770 low-frequency events (5-50 Hz): (1) Shallow events are highly clustered, consistent with the pathway from injection well 13-10A to monitoring well; moment tensor inversion shows dominant tensile cracking; (2) Deep events are scattered and show migration pattern to the basement; moment tensors show that most events are shear cracks.

58 GEOSCIENCES↗
DOE OSTI2023

A bi-level data-driven framework for fault-detection and diagnosis of HVAC systems

Long-term operation of heating, ventilation, and air conditioning (HVAC) systems will eventually lead to a range of HVAC system failures, resulting in excessive energy consumption and maintenance costs. Here, to avoid HVAC malfunctioning, fault detection diagnostic (FDD) is utilized as a common practice. Machine learning methods have lately received considerable interest for FDD analysis of HVAC systems due to their high detection accuracy. Meanwhile, HVAC malfunctions are regarded as rare occurrences, hence normal operating data samples are much more accessible than data samples in faulty and malfunctioning conditions. The dominating frequency of normal operation in HVAC datasets has also led to heavily biased classification algorithms within the literature. Moreover, the focus of previous literature has been on increasing the accuracy of the models which leads to a high number of false positives (misleading alarms) in the system. In order to enhance the performance of diagnostic procedures and fill the mentioned gaps, this study proposes a novel data-driven framework. A bi-level machine learning framework is developed for diagnosing faults in air handling units (AHUs) and rooftop units (RTUs) based on principal component analysis (PCA), time series anomaly detection, and random forest (RF). It is shown that PCA can reduce the dataset dimension with one principal component accounting for 95% of data variance. Also, the random forest could classify the faults with 89% precision for single-zone AHU, 85% precision for RTU, and 79% for multi-zone AHU. By proposing this framework, three persistent challenges are addressed: (I) minimizing false positives; (II) accounting for data imbalance; and (III) normal condition monitoring of equipment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Seismicity-constrained fault detection and characterization with a multitask machine learning model

Geological fault detection and characterization are crucial for understanding subsurface dynamics across scales. While methods for fault delineation based on either seismicity location analysis or seismic image reflector discontinuity are well-established, a systematic approach that integrates both data types remains absent. We develop a novel machine learning model that unifies seismic reflector images and seismicity location information to automatically identify geological faults and characterize their geometrical properties. The model encodes a seismic image and a seismicity location image separately, and fuses the encoded features with a spatial-channel attention fusion module to improve the learning of important features in both inputs. We design an automated strategy to generate high-quality synthetic training data and labels. To improve the realism of the seismicity location image, we include random seismicity noise and missing seismicity location associated with some of the faults. We validate the model’s efficacy and accuracy using synthetic data examples and two field data examples. Moreover, we show that fine-tuning the trained model with a small, domain-specific dataset enhances its fidelity for field data applications. The results demonstrate that integrating seismicity location and seismic images into a unified framework allows the end-to-end neural network to achieve higher fidelity and accuracy in delineating subsurface faults and their geometrical properties compared with image-only fault detection methods. Our approach offers an adaptive data-driven tool for geological fault characterization and seismic hazard mitigation, bridging the gap between seismicity location and image-based fault detection methods.

58 GEOSCIENCES↗
DOE OSTI2026

Protection System Validation Using Post-Event Anomaly Classification with Machine Learning

Power system protection devices have transitioned over the past few decades from mechanical to analog devices, then to solid state and finally digital. Relays and their associated critical network of equipment have significantly increased in complexity. Even internally, relays have gained significant intricacy, with relatively simple overcurrent or differential functions now being assisted by a myriad of other functions. This is necessary as the grid becomes more complex, but it brings increased difficulty in monitoring and upkeep. Misoperation caused by improper relay settings or malicious actions is a constant challenge faced by all utilities. These improper settings can be difficult to identify and may require exhaustive post-mortem analysis, typically after a major outage event has already occurred. A mechanism is needed for monitoring the behavior of protection systems to validate that they act and perform as expected. This work presents a concept for a machine learning (ML) system capable of validating the performance of protection systems by classifying anomalous events and characterizing protection system responses based solely on available current and voltage measurements. As a first step in its development, an experimental dataset is generated, and a random forest model is implemented with high accuracy in distinguishing four power system scenarios.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Line Faults Classification Using Machine Learning on Three Phase Voltages Extracted from Large Dataset of PMU Measurements

An end-to-end supervised learning method is developed to classify transmission line faults in a twoyear field-recorded dataset that includes synchronized measurements of three-phase voltages recorded by 38 Phasor Measurement Units (PMU) sparsely located in in the US Western Grid interconnection. Statistical analysis is performed to extract features from this large dataset to train Support Vector Machine (SVM), Random Forest (RF), and eXtreme Gradient Boosting (XGBoost) classifiers initially. The training further leverages a simulated dataset from a synthetic grid with 12 PMUs to increase the number of faults of types infrequently seen in the field-recorded dataset. Training the classification models with the combined dataset resulted in a classification accuracy of 97.7%. This is a significant improvement over 89.7% to 92.5% accuracy obtained by relying on the field-recorded dataset alone.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Gulf of Mexico Risk Analysis Database (GoMRAD)

The Gulf of Mexico Risk Analysis Database is comprehensive Esri geodatabase of vector layers, raster layers, and tables curated for risk analysis within the offshore Gulf of Mexico. Datasets include bathymetry, seafloor characteristics (channels, anomalies, faults, etc.), MetOcean data (wind speed, wave height, etc.), ocean current data, sediment data, and machine learning training regions used in NETL's Ocean & Geohazard Analysis (OGA) tool. This database serves as a compliment to the OGA tool by providing many of the datasets used in the design of the OGA tool, including regions used for machine learning. This database also serves as a valuable resource for risk analysis studies within the offshore Gulf of Mexico. This work was completed under the Advanced Offshore Research Portfolio, FWP Number: 1022476.

BOEM,Bathymetry,Gulf Of Mexico,Machine Learning,Me↗
DOE OSTI2024

Long-Term Statistical Process Monitoring of an Ultrafiltration Water Treatment Process

As water treatment technology has improved, the amount of available process data has substantially increased, making real-time, data-driven fault detection a reality. One shortcoming of the fault detection literature is that methods are usually evaluated by comparing their performance on hand-picked, short-term case studies, which yields no insight into long-term performance. In this work, we first evaluate multiple statistical and machine learning approaches for detrending process data. Then, we evaluate the performance of a PCA-based fault detection approach, applied to the detrended data, to monitor influent water quality, filtrate quality, and membrane fouling of an ultrafiltration membrane system for indirect potable reuse. Based on two short case studies, the adaptive lasso detrending method is selected, and the performance of the multivariate approach is evaluated over more than a year. The method is tested for different sets of three critical tuning parameters, and we find that for long-term, autonomous monitoring to be successful, these parameters should be carefully evaluated. However, in comparison with industry standards of simpler, univariate monitoring or daily pressure decay tests, multivariate monitoring produces substantial benefits in long-term testing.

ammonia↗
DOE OSTI2026

Validating Protection System Behavior with Machine Learning in a Master State Overseer

As power system protection devices continue the widespread transition from analog to digital, they become increasingly intricate. The internal functions and communication between critical grid components must now be significantly more complex to keep up with the demands of the modern smart grid. This brings increased difficulty in maintenance and monitoring, making it harder to identify potential misoperation, power anomalies, and cyber threats. Such issues are often only pinpointed after an exhaustive and costly post-mortem analysis, when a major outage or damage has already occurred. A solution is needed for validating protection systems as they operate, independently evaluating grid state and confirming whether the protection system is behaving accordingly. As opposed to incident response, this acts as a constant verification mechanism that raises a flag when subtler issues are noticed, catching them earlier and preventing larger incidents. This work presents the implementation of such a system, expanding on the prototype developed by the authors in a previous paper. This is accomplished with a machine learning (ML) system capable of validating the performance of protection systems by classifying anomalous events and characterizing protection system responses based solely on available current and voltage measurements. Additionally, this system is contextualized within a larger, modular Master State awareness Overseer (MSO) framework, responsible for monitoring, analyzing, and managing an electric grid.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Condition monitoring of permanent magnet AC machines for all-electric transportation systems: State of the art

The current state of the art on emerging and efficient techniques for condition monitoring of permanent magnet (PM) alternating-current (AC) machines deployed in electric vehicle (EV) applications is presented. The discussion includes the most common and specific types of faults in PM motors, such as rotor demagnetisation and stator inter-turn faults, respectively. Fault indicators, such as voltage (v s ) and current (i s ) signals and machine signatures based on motor back electromotive force (EMF) (E B ) and magnetic flux (φ), are taken into account as a measuring quantity in diagnosing motor faults. Other signatures, including thermal analysis, acoustic noise, and vibrations, are also illustrated as some of the emerging techniques in estimating the performance of EV motors while under operations. In addition, various fault modelling methods, condition monitoring techniques, and comprehensive approaches applied in diagnosing the effect of machine faults during its incipient stages are illustrated. Since most of the fault diagnostic techniques discussed here include only machine-based quantities as fault indices/indicators, the provided solutions are therefore found to be more reliable and accurate for diagnosing the motor faults. This comprehensive review study is inclusive of the existing fault diagnostic techniques, which are currently employed in industrial and commercial practices, in addition to the new methodologies proposed by the authors. All the given condition monitoring schemes therefore seem significantly vital in estimating the state of health of PM AC machines while under operation in all-electric transportation systems.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Machine Learning Using a Simple Feature for Detecting Multiple Types of Events From PMU Data

This paper describes simple and efficient machine learning (ML) methods for efficiently detecting multiple types of power system events captured by PMUs scarcely placed in a large power grid. It uses a single feature from each PMU based on a rectangle area enclosing the event in a given data window. This single feature is sufficient to enable commonly used ML models to detect different types of events quickly and accurately. The feature is used by five ML models on four different data-window sizes. The results indicated a tradeoff between the execution speed and detection accuracy in variety of data-window size choices. Here, the proposed method is insensitive to most data quality issues typical for data from field PMUs, and thus it does not require major data cleansing efforts prior to feature extraction.

Big data↗
DOE OSTI2022

A physics‐informed learning technique for fault location of DC microgrids using traveling waves

Abstract Fast and accurate fault location in DC power systems is of particular importance to ensure their reliable operation. One of the approaches for implementing a fast‐tripping protection scheme is to use Traveling waves (TW) initiated by a fault scenario. This paper proposes a physics‐informed machine learning approach that utilizes TWs for fault location in DC microgrids. TWs are extracted by the so‐called multiresolution analysis which identifies the TW's wavelet coefficients for multiple frequency ranges. This paper deploys Parseval's theorem to find the energy of wavelet coefficients as a quantitative metric for describing TWs. The hypothesis of this paper is that once the Parseval energy curves for a specific cable are extracted, they can be utilized to locate faults along with that cable regardless of the DC system in which the cable is deployed. The fault location algorithm uses Parseval energy curves to train a Gaussian Process (GP) estimator. With the Parseval energy values of measured current at the protection device location, the GP estimator is able to estimate fault locations with high accuracy. The effectiveness of the proposed algorithm is verified by simulating a DC microgrid system in PSCAD/EMTDC.

Paruthiyil, Sajay Krishnan↗