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Abstract Recently, prognostic and health management (PHM) has become a prominent field in modern industry. The rotate vector (RV) reducer is one of the widely used mechanical components in industrial systems, specifically in robots. The RV reducer is known for its unique characteristics of small size, efficient speed transmission, and high torsion. The RV reducer is prone to several kinds of faults, due to its continuous operation in an industrial robot. To keep the operation smooth and steady, timely PHM of the RV reducer has become essential. Previously, the RV reducer fault was diagnosed via various techniques, such as ferrography analysis, vibration analysis, and acoustic emission analysis. However, these conventional techniques have various issues. To resolve those issues, we introduce a novel approach to use the embedded electrical current system for the fault detection of the RV reducer. However, this is quite complicated to investigate mechanical fault using an electrical current signature, since the RV reducer is not an integral part of the electric motor, and finding a fault pattern in faulty components needs thorough examination. We therefore focus on the application of machine learning (ML) for fault classifications. We present an approach for feature extraction, feature selection, and feature reduction using the information obtained from the motor current signature analysis to create an ML-based fault classification system with distinguishable prominent features. Finally, the authenticity of the presented approach is justified via the improved values of evaluating parameters, such as accuracy, specificity, and sensitivity, for ML classifiers. Graphical Abstract Graphical Abstract

Induction motors are widely used in industry and are essential to industrial processes. The faults in motors lead to high repair costs and cause financial losses resulting from unexpected downtime. Early detection of faults in induction motors has become necessary and critical in reducing costs. Most motor faults are caused by bearing failure. Machine learning-based diagnostic methods are proposed in this study. These methods use effective features. First, load currents of healthy and faulty motors are measured while the rotating speed is changing continuously. Second, experiments revealed the relationship between the magnitude of the amplitude of specific signals and the rotating speed, and the rotating speed is treated as a new feature. Third, machine learning-based diagnoses are conducted. Finally, the effectiveness of machine learning-based diagnostic methods is verified using experimental data.

Purpose Early detection of impending faults in centrifugal pumps could lower the repair and maintenance costs. Electrical Signature Analysis (ESA) is a powerful tool which uses the voltage and current signals of the motor driving the pump to infer the health status. In this study, we strive to develop an ESA-based algorithm to perform fault diagnosis for a centrifugal pump. Methods Support vector machine (SVM), derived from the statistical learning theory (SLT), is a relatively new technique based on the structural risk minimization principle. This paper presents the application of SVM algorithm in junction with ESA for fault diagnosis of a motor-driven centrifugal pump. To do this, SVM is formulated as a multi-class classification problem and suitable features from electrical signals are devised as the inputs to the SVM classifier. Results Experimental results show the effectiveness of the proposed method in detecting and diagnosing main types of pump faults with high accuracy. Conclusion Fault diagnosis of motor-driven centrifugal pumps can be carried out using only the electrical signals of the motor, i.e. voltage and current. This alleviates the need to install accelerometers for vibration sensing and allows for continuous monitoring of the target equipment.

Neodymium-boron (NdFeB) permanent magnets (PMs) have been widely studied in the past years since they became the material of choice in permanent magnet synchronous machines (PMSMs). Although NdFeB PMs have a better energy density than other types of magnets and are cost-effective, their magnetization is very sensitive to the PMSM operating conditions, in particular temperature, where the irreversible demagnetization degree increases over time. Therefore, it is important to characterize and diagnose demagnetization at an early stage. In this context, this paper proposes a two-step analysis study dealing with both uniform and partial demagnetization. A 2D finite element method-based (FEM) approach is used for demagnetization characterization, and then a PMSM motor current signature analysis (MCSA) approach, based on fast Fourier transform (FFT), is considered where fault cases harmonics are considered as faults indices to detect demagnetization. In some situations, the proposed two-step approach achieved results that clearly allow distinguishing and characterizing demagnetization. Indeed, a local demagnetization introduces specific sub-harmonics while a uniform demagnetization leads to the current amplitude increase for a given torque.

The growing number of variable speed drives (VSDs) in industry has an impact on the future development of condition monitoring methods. In research, more and more attention is being paid to condition monitoring based on motor current evaluation. However, there are currently only a few contributions to current-based pump diagnosis. In this paper, two current-based methods for the detection of bearing defects, impeller clogging, and cracked impellers are presented. The first approach, load point-dependent fault indicator analysis (LoPoFIA), is an approach that was derived from motor current signature analysis (MCSA). Compared to MCSA, the novelty of LoPoFIA is that only amplitudes at typical fault frequencies in the current spectrum are considered as a function of the hydraulic load point. The second approach is advanced transient current signature analysis (ATCSA), which represents a time-frequency analysis of a current signal during start-up. According to the literature, ATCSA is mainly used for motor diagnosis. As a test item, a VSD-driven circulation pump was measured in a pump test bench. Compared to MCSA, both LoPoFIA and ATCSA showed improvements in terms of minimizing false alarms. However, LoPoFIA simplifies the separation of bearing defects and impeller defects, as impeller defects especially influence higher flow ranges. Compared to LoPoFIA, ATCSA represents a more efficient method in terms of minimizing measurement effort. In summary, both LoPoFIA and ATCSA provide important insights into the behavior of faulty pumps and can be advantageous compared to MCSA in terms of false alarms and fault separation.

Motor Current Signature Analysis (MCSA) is a commonly used non-invasive method for diagnosing faults in electric motors. Although MCSA provides significant advantages—current signals are easy to acquire and inherently robust against noise—this study aims to further enhance its diagnostic capabilities by focusing on symmetrical components. Three-phase stator current signals are converted into zero, positive, and negative sequence components, and their time-domain feature vectors are systematically integrated into a single image representation. A Convolutional Neural Network (CNN) is then employed for fault classification. The proposed method is model-free, requiring no explicit motor model, which offers greater flexibility compared to model-based techniques. Validation experiments were conducted on a rotor kit test bench under seven different conditions (one healthy condition and six mechanical/electrical fault conditions), with fault severities chosen to reflect practical scenarios. The symmetrical components-based image classification method demonstrated superior performance, achieving 99.76% classification accuracy and outperforming a widely used Short-Time Fourier Transform (STFT)-based spectrogram approach. These findings highlight that integrating all symmetrical component information into one image effectively captures each fault’s distinct behavior, enabling reliable diagnostic outcomes. By leveraging the distinct variations in zero, positive, and negative components under fault conditions, the proposed method offers a powerful, accurate, and non-invasive framework for real-time motor fault diagnosis in industrial applications.

Bearing health monitoring is essential for ensuring the reliability and operational safety of induction machines, as bearing faults remain among the most frequent failure modes in rotating electrical equipment. This work contributes to condition monitoring by enhancing the robustness of health indicators and developing a supply-frequency-independent health indicator (HI) for bearing fault diagnosis using Motor Current Signature Analysis (MCSA). The objective is to design an HI capable of reliably representing the bearing degradation state under varying operating conditions, particularly when the supply frequency changes. To achieve this, the study briefly examines the key physical mechanisms governing the detectability of bearing-related spectral signatures—including rotational frequency, unbalanced magnetic pull, eddy currents, skin effect, and hydrodynamic forces. The theoretical analysis establishes the overall trend expected under varying supply frequencies and clarifies how these phenomena collectively influence the spectral characteristics of the fault components and the frequency-dependent evolution of their amplitudes. These insights are experimentally validated using induction machines fitted with bearings of two fault severities. Leveraging this physical understanding, a modified regression-based compensation model is introduced to reduce the frequency-dependent variation in the HI. The resulting compensating factor effectively stabilizes the frequency response, producing a more consistent and monotonic degradation trend across the tested conditions. The proposed method is computationally lightweight, does not require run-to-failure data or detailed physical modeling, and is suitable for real-time implementation. By integrating physical insight with data-driven modeling, this work presents a practical and frequency-independent HI framework that can be readily deployed within digital-twin-based condition monitoring architectures for induction machines.

The concept of a digital twin is increasingly appearing in industrial applications, including the field of predictive maintenance. A digital twin is a virtual representation of a physical system containing all data available on site. This paper presents condition monitoring of ventilation systems through the digital twin approach. A literature review regarding the most popular system faults is covered. The motor current signature analysis is used in this research to detect system faults. The physical system is further described. Then, based on the free body diagram concept and Newton’s second law, the equations of motion are obtained. Matlab/Simulink software is used to build the digital twin. The Concordia method and the Fast Fourier Transform analysis are used to process the current signal, and physical and numerical system current measurements are obtained and compared. In the final step of the modeling, specific frequencies were adjusted in the twin to achieve the best simulation. In addition, a statistical approach is used to create a complete diagnostic protocol.

Heating, ventilation, and air conditioning system runtime is a crucial metric for establishing the connection between system operation and energy performance. Similar homes in the same location can have varying runtime due to different factors. To understand such heterogeneity, this study conducted an energy signature analysis of heating and cooling system runtime for 5,014 homes across the US>using data from ecobee smart thermostats. Two approaches were compared for the energy signature analysis: (1) using daily mean outdoor temperature and (2) using the difference between the daily mean outdoor temperature and the indoor thermostat setpoint (delta T) as the independent variable. The best-fitting energy signature parameters (balance temperatures and slopes) for each house were estimated and statistically analyzed. The results revealed significant differences in balance temperatures and slopes across various climates and individual homes. Additionally, we identified the impact of housing characteristics and weather conditions on the energy signature parameters using a long absolute shrinkage and selection operator (LASSO) regression. Incorporating delta T into the energy signature model significantly enhances its ability to detect hidden impacts of various features by minimizing the influence of setpoint preferences. Moreover, our cooling slope analysis highlights the significant impact of outdoor humidity levels, underscoring the need to include latent loads in building energy models.

Stator turn-to-turn faults occur due to improper loading, eccentricity in the rotor, and increases in the operating temperature. During the occurrence of a stator turn-to-turn fault, an abnormal temperature increase occurs, and if this state is left unattended for a long duration, it can lead to degradation of the permanent magnet. This paper presents an analytical modeling scheme for surface permanent magnet brushless DC motors for diagnosing and classifying stator turn-to-turn faults using SIMULINK ® during non-stationary operating conditions. A significant increase in the stator current, back EMF, torque, and speed is observed. A current signature analysis is performed during non-stationary operating conditions using a fast Fourier transform method to identify the severity of the fault. Furthermore, a simple and efficient classification model is developed by selecting the best classifier among the decision trees, neural network, support vector machine, discriminant analysis, and ensemble classifier. A statistical evaluation of the current signal for fault feature extraction and ranking is performed based on minimum redundancy and maximum relevance, Chi-square test, Relief F, analysis of variance, and Kruskal–Wallis test. The dataset for classification is extracted from a Simulink analytical model. Neural network-based classifiers can classify faults precisely and rapidly with a minimum number of features.