Abstract
We introduce a new approach for online and offline soft fault diagnosis in motor power cables, utilizing periodic burst injection and nonintrusive capacitive coupling. We focus on diagnosing soft faults because local cable modifications or soft faults that occur without any indication while the cable is still operational can eventually develop into hard faults; furthermore, advance diagnosis of soft faults is more beneficial than the later diagnosis of hard faults, with respect to preventing catastrophic production stoppages. Both online and offline diagnoses with on-site diagnostic ability are needed because the equipment in the automated lines operates for 24 h per day, except during scheduled maintenance. A 1D CNN model was utilized to learn high-level features. The advantages of the proposed method are that (1) it is suitable for wiring harness cables in automated factories, where the installed cables are extremely short; (2) it can be simply and identically applied for both online and offline diagnoses and to a variety of cable types; and (3) the diagnosis model can be directly established from the raw signal, without manual feature extraction and prior domain knowledge. Experiments conducted with various fault scenarios demonstrate that this method can be applied to practical cable faults.
Highlights
IntroductionWith the growth of fully automated production lines in modern manufacturing, the early detection of faults in the motor power cable of automation machinery has become a demanding requirement to reduce unscheduled maintenance
A single hard fault in the motor cable could result in unplanned production line downtime because the machines need to be taken offline to ensure safety during inspection
Dataset 0 in Table 2a was used as the training and validation sets for the 1D convolutional neural network (1D CNN)
Summary
With the growth of fully automated production lines in modern manufacturing, the early detection of faults in the motor power cable of automation machinery has become a demanding requirement to reduce unscheduled maintenance. A single hard fault in the motor cable could result in unplanned production line downtime because the machines need to be taken offline to ensure safety during inspection. This catastrophic production line stoppage could result in a huge loss of productivity. For this reason, the integrity of the motor cables in manufacturing automation, such as automotive factory floors, must be ensured for safe operation. Offline diagnostics are still required for regular maintenance when the machine can be offline for preventive maintenance
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