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Abstract A fault diagnosis system in a multilevel-inverter using induction motors. The protection devices will disconnect the
a compact neural network is proposed in this paper. It is power sources from the multilevel inverter system whenever a
difficult to diagnose a multilevel-inverter drive (MLID) system fault occurs, stopping the operated process. Downtime of
using a mathematical model because MLID systems consist of manufacturing equipment can add up to be thousands or
many switching devices and their system complexity has a
hundreds of thousands of dollars per hour, therefore fault
nonlinear factor. Therefore, a neural network classification is
applied to the fault diagnosis of a MLID system. Multilayer detection and diagnosis is vital to a companys bottom line.
perceptron (MLP) networks are used to identify the type and In order to maintain continuous operation for a multilevel
location of occurring faults from inverter output voltage inverter system, knowledge of fault behaviors, fault
measurement. The neural network design process is clearly prediction, and fault diagnosis are necessary. Faults should
described. The principal component analysis (PCA) is utilized to be detected as soon as possible after they occur, because if a
reduce the neural network input size. A lower dimensional input motor drive runs continuously under abnormal conditions, the
space will also usually reduce the time necessary to train a neural drive or motor may quickly fail.
network, and the reduced noise may improve the mapping The various fault modes of a conventional PWM voltage
performance. The comparison between MLP neural network
source inverter (VSI) system for an induction motor are
(NN) and PC neural network (PC-NN) are performed. Both
proposed networks are evaluated with simulation test set and investigated in [2]. Then, the integration of a fault diagnosis
experimental test set. The PC-NN has improved overall system into VSI drives is described in [3]. This integration
classification performance from NN by about 5% points. The system introduced remedial control strategies soon after
overall classification performance of the proposed networks is failure occurrences; therefore, system reliability and fault
more than 90%. Thus, by utilizing the proposed neural network tolerant capability are improved.
fault diagnosis system, a better understanding about fault A noninvasive technique for diagnosing VSI drive
behaviors, diagnostics, and detections of a multilevel inverter failures based on the identification of unique signature
drive system can be accomplished. The results of this analysis are patterns corresponding to the motor supply current Parks
identified in percentage tabular form of faults and switch
Vector is proposed in [4]. A study of a machine fault
locations.
diagnosis system by using FFT and neural networks is clearly
Index Terms Fault diagnosis, multilevel inverter, principal explained in [5]. Also, a fault diagnosis system for rotary
component, neural network. machines based on fuzzy neural networks is developed in [6].
The possibilities offered by a neural network for fault
diagnosis and system identification are investigated in [7].
I. INTRODUCTION Furthermore, a new topology with fault-tolerant ability that
improves the reliability of multilevel converters is proposed in
In recent years, industry has begun to demand higher
[8]. A method for operating cascaded multilevel inverters
power ratings, and MLID systems have become a solution for
when one or more power H-bridge cells are damaged has been
high power applications. A multilevel inverter not only
proposed in [9]. The method is based on the use of additional
achieves high power ratings, but also enables the use of
magnetic contactors in each power H-bridge cell to bypass the
renewable energy sources. Two topologies of multilevel
faulty cell. One can see from the literature survey that the
inverters for electric drive application have been discussed in
knowledge and information of fault behaviors in the system is
[1]. The cascade MLID is a general fit for large automotive
important to improve system design, protection, and fault
all-electric drives because of the high VA rating possible and
tolerant control. Thus far, limited research has focused on
because it uses several level dc voltage sources which would
MLID fault diagnosis. Therefore, a MLID fault diagnosis
be available from batteries or fuel cells [1].
system is proposed in this paper that only requires
A schematic of a single phase multilevel inverter system
measurement of the MLIDs voltage waveforms.
is illustrated in Fig. 1. Because multilevel inverter systems are
An example of a MLID open circuit fault at switch SA+ is
utilized in high power applications, the reliability of the power
represented in Fig. 2. SA+ fault will cause unbalanced voltage
electronics equipment is very important. For example,
and current output, while the induction motor is operating.
industrial applications such as industrial manufacturing are
The unbalanced voltage and current may result in vital
dependent upon induction motors and their inverter systems
damage to the induction motor if the induction motor is run in
for process control. Generally, the conventional protection
this state for a long time. The unbalanced condition from fault
systems are passive devices such as fuses, overload relays,
SA+ can be solved if the fault location is correctly identified.
and circuit breakers to protect the inverter systems and the
Switching patterns and the modulation index of other active
switches in the MLID can be adjusted to maintain output Vdc
Multilevel Inverter Induction
voltage and current in a balanced condition. Although the System Motor
Vdc
MLID can continuously operate in a balanced condition, the
MLID will not be able to operate at its rated power.
the MLID system usually consists of three phases of H-bridge Neural network fault
classification
inverters and also can have short circuit faults, the fault
Output
diagnosis system will be the same topology as a single phase
Input
and open circuit case. Moreover, one level of a multilevel
inverter is focused in this research; however, other inverter
levels can be extended by using this proposed topology with
Fig. 3. Structure of fault diagnosis system.
more training data. The proposed network utilizes output
voltage signals of the MLID to train the neural networks. The
acquired data is transformed by using Fast Fourier Transform II. FAULT DIAGNOSIS SYSTEM
technique to rate a signal value as an important characteristic
[10]. Then, the PCA is performed to reduce the input neural
A. Structure of Fault Diagnosis System
size [11-12]. The signal feature extraction is discussed, and
the process of neural network design is fully described. The structure for a fault diagnosis system is illustrated in
Fig. 3. The system is composed of four major states: feature
H-Bridge 2 extraction, neural network classification, fault diagnosis, and
Va switching pattern calculation with gate signal output. The
SA+ SB+ feature extraction, neural classification, and fault diagnosis are
+ SDCS
the focus of this research. The feature extraction performs the
va 2 V dc
- voltage input signal transformation, with rated signal values as
SA- SB- important features, and the output of the transformed signal is
transferred to the neural network classification. The networks
H-Bridge 1
are trained with both normal and abnormal data for the MLID;
SA+ SB+ thus, the output of this network is nearly 0 and 1 as binary
+ SDCS code. The binary code is sent to the fault diagnosis to decode
va 1 V dc the fault type and its location. Then, the switching pattern is
n -
calculated to reconfigure the MLID to bypass the failed level.
SA- SB-
B. Feature Extraction System and Principal Component
Analysis
Fig. 1. Single-phase multilevel-inverter system
Simulated and experimental output voltages are illustrated
in Fig. 4. As can be seen, the signals are difficult to rate as an
H-Bridge 2 important characteristic for classifying a fault hypothesis, and
Va they have high correlation with each other. Therefore, a signal
SA+ SB+ transformation technique is needed. The transformed signals
+ SDCS using FFT of both simulation and experiment are represented
va 2 V dc
-
in Fig. 5. Obviously, the results are satisfactory for identifying
fault features. The FFT technique has a good identity feature to
SA- SB-
classify normal and abnormal features. However, many
neurons are used to train the network (i.e. one neuron for each
H-Bridge 1 harmonic); therefore, PCA is used to reduce the number of
SA+ SB+ input neurons as illustrated in Fig. 6. PCA is a method used to
+ SDCS reduce the dimensionality of an input space without losing a
va 1 V dc significant amount of information (variability) [13]. The
n -
method also makes the transformed vectors orthogonal and
SA- SB-
uncorrelated. A lower dimensional input space will also
usually reduce the time necessary to train a neural network,
and the reduced noise (by keeping only valuable PCs) may
Fig. 2. H-Bridge 2, Switch SA+ open circuit fault at second level of single-
phase multilevel-inverter. improve the mapping performance. The detail of PCA and
neural network design will be discussed in the next section.
Fault Diagnosis Simulation FFT Simulation
20 20
Notmal
Normal
0 10
-20 0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 5 10 15 20 25 30 35
20 20
Fault A+
Fault A+
0 10
-20 0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 5 10 15 20 25 30 35
20 20
Fault A-
Fault A-
0 10
-20 0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 5 10 15 20 25 30 35
20 20
Fault B+
Fault B+
0 10
-20 0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 5 10 15 20 25 30 35
20 20
Fault B-
Fault B-
0 10
-20
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 5 10 15 20 25 30 35
Input data Harmonic order
(a) (a)
Fault Diagnosis Experiment FFT Experiment
20
20
Normal
Normal
0 10
-20 0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 5 10 15 20 25 30 35
20 20
Fault A+
Fault A+
0 10
-20 0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 5 10 15 20 25 30 35
20 20
Fault A-
Fault A-
0 10
-20 0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 5 10 15 20 25 30 35
20 20
Fault B+
Fault B+
0 10
-20 0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 5 10 15 20 25 30 35
20 20
Fault B-
Fault B-
0 10
-20
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 5 10 15 20 25 30 35
Input data Harmonic order
(b) (b)
Fig. 4. (a) Simulation and (b) experimental results of fault features at SA+, Fig. 5. Signal transformation of (a) simulation and (b) experiment of output
SA-, SB+, and SB- of H-bridge 2 with modulation index = 0.8 out of 1.0. voltages by using FFT with modulation index = 0.8 out of 1.0.
Data Scores
C. Experimental Setup t1
X1 t2
X2 t3
The experiment setup is represented in Fig. 7. A three-
X3 Neural Network Y
X4
PCA Classification
phase wye-connected cascaded multilevel inverter using 100 X5
T = XP (1)
where:
T is the mk score matrix (transformed data)
m = the number of observations
Multilevel Inverter
Separated DC Source k = dimensionality of the PC space
(SDCS)
X is the mn data matrix.
m = the number of observations
Fig. 7. Experiment setup. n = dimensionality of original space
P is the nk loadings matrix (PC coordinates)
n = dimensionality of original space
k = number of the PCs kept in the model
t11 t12 t1k x11 x12 x1n p11 p12 p1k
t 21 t 22 t 2 k = x21 x22 x2 n p21 p 22
p2k
(2)
t m1 t m 2 t mk xm1 xm 2 xmn pn1 p n 2 p nk
(m k ) = (m n) (n k )
(3)
pn1 pn 2 pnk
(1 k ) = (1 n) (n k )
Loadings on PC#1
response time of the original procedure presented for the on- 0.2
Scores on PC#1
5
component neural network fault classification are explained in
the following. 0
A. Data Analysis -5
0 5 10 15 20 25 30 35 40 45 50
The data from the FFT are transformed to principle Sample
Loadings on PC#4
of the covariance matrix of the original input data (XC), and 0.2
other PCs are less than 1; this means the PCs have less 6
from the plot in Fig. 9 that the break is between 5 and 8 PCs; 0
optimum model. -4
0 5 10 15 20 25 30 35 40 45 50
The collected data from both simulation and experiment Sample
samples are normal condition, the next 5 samples are Fault 0.2
A+, the next 5 samples are Fault A-, the next 5 samples are 0
Fault B+, and the next 5 samples are Fault B-. The next 25
-0.2
samples are unknown samples for testing the proposed neural
networks. Clearly, the first PC can be used to distinguish -0.4
0 5 10 15 20 25 30 35 40 45
between normal and fault conditions. We can see that the first Variable
have mostly negative scores. We also see that the first PCs are 4
Scores on PC#3
Eigenvalues 0
8
-2
6 -4
0 5 10 15 20 25 30 35 40 45 50
4 Sample
2
(c)
0 Fig. 10. The selected plot of principal components score and loading; (a)
0 5 10 15 20 25 30 35 40 first PC, (b) fourth PC, and (c) third PC
Cumulative % Variance Explained
100 Also, the 4th PC can be used to classify the different
features between Fault A+ and A- and Fault B+ and B-.
However, the 3rd PC may not be useful because the 3rd PC
50 could not reveal any classification information as shown in
Fig. 10 (c), although it contains more information and
variance (Eigenvalue) than the 4th. Therefore, in this research,
0
0 5 10 15 20 25 30 35 40 the combination of 1, 2, 4, 6 and 8 principal components are
Principal Component
used to perform the neural network classifications. The 3-D
Fig. 9. The plot of principal components versus eigenvalues.
plots of PC scores are shown in Fig. 11. We can see that the
classification between normal and faults could be a linear
problem, whereas the classification among faults is a
6
nonlinear problem. That is why the neural network is applied Normal
4
to solve this problem. By using PCA, the size of input Fault A+
Fault A-
2
neurons can be reduced from 40 nodes to 5 nodes. (i.e. 5 Fault B+
Score PC1
Fault B-
harmonics instead of 40 harmonic components) 0
-2
-2
nodes, 4 hidden nodes, and 3 output nodes as proposed in -4 -4
-2
Score PC 8 Score PC 6
[16]. The original data from the feature extraction system
(FFT) is used in this network. The second NN architecture has (a)
one hidden layer with 5 input nodes, 3 hidden nodes, and 3
output nodes. The PCA is applied in this network to reduce
the number of input neurons. The sigmoid activation function
6
is used in both NNs: tansig for hidden nodes and logsig for an Normal
4
output node. A logsig activation function is used for an output Fault A+
Fault A-
2
node because the target output is between 0 and 1 [11, 16]. Fault B+
Score PC1
0 Fault B-
C. Input/Output Data -2
-4
The set of original input data at each MLID operation
contains 5 classes: normal data (normal condition) and four -6
4
abnormal data (Fault A+ A- B+ B-). The MLID operation will 2 4
2
be changed with desired load, so modulation index must be 0
-2
0
-2
changed. In this research, modulation indices are varied from Score PC6 -4 -4
Score PC2
0.6 to 1 with 0.05 intervals. Therefore, the original data
contains 45 observers covering all possible operations. The (b)
output target nodes are coded with a binary code as shown in Fig. 11. The 3-D plots of PC scores; (a) score on PC 6, 8, 1, (b) score
the Table I. The round ( ) function is used to make the binary on PC 2, 6, 1.
code outputs for the test sets. Second, the test set is measured from experiment at
D. Neural Network Training different modulation indices of 0.7, 0.8, 0.9, and 1 as shown in
Fig. 5(b) and 8. Training and testing sets have 200 kHz
The Levenberg Marquardt training paradigm, trainlm is sampling frequency. Both data sets are transformed by FFT
utilized in this research because trainlm not only performs very from 0 to 39 harmonic orders. Zero harmonic order means the
fast training time but also has inherent regularization properties dc component of the signals. Again, it should be noted that
[11]. Regularization is a technique which adds constraints so each modulation index has 5 classifications: normal, Fault A+,
that the results are more consistent. The 1% misclassification A-, B+ and B-. The test sets are used to examine the neural
and 1% input data error rate are chosen to calculate a sum of network classification performance. It should be noted that the
square error goal, SSE; therefore, a SSE < 0.025 goal is used to input training and testing data are scaled by using the mean
train the network by calculating from (4). The training process center and unit variance method as explained in [16].
will be finished when the SSE goal is met.
n V. FAULT CLASSIFICATION RESULTS
SSE = ( y yi ) 2 (4)
i =1 The performance of the proposed networks is tested in two
where y is the output target binary codes, categories. First, the networks are tested with the simulation
test sets as previously mentioned. Second, the networks are
yi is output of training data, evaluated with the experimental test set. The tested results
n is the number of training data, along with the testing data sets are illustrated in Table I.
E. Training and Testing Data Set Selection Clearly, in the simulation test set, both NN and PC-NN have a
good classification performance (about 95%); therefore, the
The training data set should also cover the operating classification performance of the networks is quite satisfactory.
region, thus the training set is generated from simulation with The misclassification samples are the same operation point and
various operation points (different modulation indices, 0.6, 0.7, class which are 0.65 modulation index and fault B-. This result
0.8, 0.9 and 1). The testing sets have two different sources: suggests that both networks have confusion between Fault A-
first, the test set is generated from simulation with modulation and Fault B- at low modulation index.
indices, 0.65, 0.75, 0.85, and 0.95.
TABLE I
CONFUSION TABLE FOR MLID H-BRIDGE
Actual Output % Classification
Testing set Target
NN PC-NN NN PC-NN
1 1 1 1 1 1
Normal 1 1 1 1 1 1 100% 100%
[1 1 1] 1 1 1 1 1 1
1 1 1 1 1 1
0 0 1 0 0 1
Fault A+ 0 0 1 0 0 1
100% 100%
[0 0 1] 0 0 1 0 0 1
0 0 1 0 0 1
0 1 0 0 1 0
Fault A- 0 1 0 0 1 0
Simulation test set 100% 100%
[0 1 0] 0 1 0 0 1 0
0 1 0 0 1 0
1 0 1 1 0 1
Fault B+ 1 0 1 1 0 1
100% 100%
[1 0 1] 1 0 1 1 0 1
1 0 1 1 0 1
1 1 0 1 1 0
Fault B- 1 1 0 1 1 0
75% 75%
[1 1 0] 1 1 0 1 1 0
0 1 0 0 1 0
% Classification performance in simulation test set 95% 95%
1 1 1 1 1 1
Normal 1 1 1 1 1 1
100% 100%
[1 1 1] 1 1 1 1 1 1
1 1 1 1 1 1
0 1 1 0 0 1
Fault A+ 0 1 1 0 0 1
75% 100%
[0 0 1] 0 1 1 0 0 1
0 1 0 0 0 1
0 1 0 0 1 0
Fault A- 0 1 0 0 1 0
Experimental test set 75% 100%
[0 1 0] 0 1 0 0 1 0
0 0 1 0 1 0
1 0 1 1 0 1
Fault B+ 1 0 1 1 0 1
100% 100%
[1 0 1] 1 0 1 1 0 1
1 0 1 1 0 1
1 1 0 1 1 0
Fault B- 1 1 0 1 1 0
75% 75%
[1 1 0] 1 1 0 1 1 0
0 1 0 0 1 0
%Classification performance in experimental test set 85% 95%
Total %Classification performance 90% 95%
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