CN115546224B - Automatic fault identification and control method for motor operation process - Google Patents
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Abstract
The invention provides a motor operation process fault automatic identification and control method, which utilizes an image sensor to continuously capture dynamic image signals in the motor operation process in real time, utilizes an image intelligent identification method to identify image signals of faults generated by a motor, and controls the motor to stop operating according to the signals, thereby achieving the purpose of protecting the motor.
Description
Technical Field
The invention belongs to the field of motor control and detection, and particularly relates to a method for automatically identifying and controlling a fault in a motor operation process.
Background
The most common fault of a dc motor is a commutation fault, which is most obviously characterized by an excessive commutation spark. Since no practical instrument is available to accurately determine the grade of the commutation spark, monitoring of the commutation spark is typically done by spot inspection workers in production practice. Manual observation of sparks relies on subjective impressions of spark characteristics and personal experience accumulation by the spotter. The observation results are inevitably affected by subjective factors.
The research of automatic spark monitoring is started from the middle of the 80's of the last century abroad and made into instruments. For example, a paper published in the international motor conference in 1992 and entitled spark monitoring system and data processing principle discloses a reversing spark monitoring system based on a photoelectric device in the motor operation process, and has the problems that the strength of an optical fiber is fragile and is easy to be broken under the driving of high-speed wind power in the motor operation process, and for a large-sized motor, the number of the optical fibers required to be arranged is as many as hundreds, so that the detection reliability of the whole system is seriously reduced. Some methods, which have been improved in recent years, such as a high-frequency disturbance detection method based on a main pole magnetic field, an electric spectrum monitoring method, a radio wave monitoring method, and the like, cannot capture the color characteristics of the spark, reducing the accuracy of detection.
With the recent advancement of image sensor technology, industrial detection methods based on image signals have become popular. From the field of motor monitoring, the monitoring method based on the image sensor can acquire the directional distribution characteristics of the reversing sparks while capturing the color characteristics of the sparks, and meanwhile, the image sensor is easy to fix in a testing environment, not easy to be influenced by non-contact wind power and good in reliability.
However, the conventional image processing methods, such as edge extraction, are generally insufficient in spark recognition accuracy and are easily interfered by the environment. Although it is also proposed to use a neural network for identification, the conventional neural networks such as CNN and FNN or their simple variants are usually adopted, and no suitable network model structure is specially designed for motor sparks, so that the problems of low detection accuracy, large calculation burden and high requirement on the number of samples exist. Particularly, in the existing neural network recognition, the collected images are directly or simply processed and then sent to the neural network, so that the requirement on the neural network structure is high, the processing effect is poor, the input data is not optimized according to the neural network structure, and the network structure is not optimized according to the input data.
Disclosure of Invention
The invention provides a motor operation process fault automatic identification and control method based on image sensor signal collection and image intelligent automatic processing, which utilizes an image sensor to continuously capture dynamic image signals in the motor operation process in real time, utilizes an image intelligent identification method to identify image signals of fault generated by the motor, and controls the motor to stop operation according to the signals, thereby achieving the purpose of protecting the motor.
A method for automatically recognizing and controlling the failure of motor in running procedure includes such steps as collecting the spark image of motor to form a digital image of visible lightAnd an ultraviolet digital image->;
Is a matrix>Is selected based on the presence of>Is an element matrix->Is greater than or equal to>Is a matrix->The total number of rows. Is a matrix->The element assignments are:
solving forIf the number of the pixels is larger than the threshold value, the spark exists in the image, otherwise, the spark does not exist;
if spark exists in the collected image, the ultraviolet digital image is processedPerforming spark pre-positioning:
whereinIndicates that the template is->Is in the position coordinate, </or is greater than or equal to>Indicating that the coordinate in the original image is pick>A convolution offset coordinate centered;
obtainingIs counted as ^ maximum position>As an ultraviolet image->Presetting a point in the center of the middle spark; normalizing the initial coordinates of all visible images to the spark center position;
utilizing a neural network to carry out spark detection based on the coordinate normalized visible light image, wherein the neural network has the structure that: the system comprises a convolution characteristic extraction layer, a multi-scale pooling layer, an orthogonal optimization layer and an output layer;
wherein the multi-scale pooling layer output is:
wherein the content of the first and second substances,、/>、/>、/>for a pooling parameter, is>Is linearly biased amount, is>Is based on an excitation function>、/>、、/>The result of the convolution feature extraction of the previous layer.
And after the spark is detected, judging that the motor fails, sending a stop signal to the motor, and controlling the motor to stop.
The model is trained using a Back Propagation (BP) algorithm.
And determining values of a convolution kernel, a pooling parameter and a linear mapping parameter through training to finish the training.
Before training, a plurality of visible light images with sparks are prepared and are used as positive samples after translation normalization.
And a plurality of visible light images without sparks are used as negative samples after translation and normalization.
The positive samples give a sample truth value 1, and the negative samples give a sample truth value 0.
And inputting the sample into the model to carry out iterative computation, comparing the true value of the sample with the output value of the model in each round, and iterating until the convergence and finishing the training.
Including by site processors and servers.
The field processor carries out acquisition image preprocessing, and the server detects and identifies the preprocessed image by utilizing the neural network and sends a control signal to the controller.
The invention has the advantages that:
1. the invention is captured by two sensors which can sense optical signals of different wave bands and are respectively positioned in a visible light wave band and an ultraviolet wave band; sparks generated by the motor can generate stronger response in an ultraviolet band relative to a visible light band, and the detection precision is improved; meanwhile, collected images are processed by using a special template and are subjected to normalization positioning, so that the environmental noise of the motor can be removed in a targeted manner, the obtained data are sent into a neural network, the detection precision can be improved, the requirement on the structural complexity of the neural network is reduced, and the calculation efficiency is improved.
2. The neural network structure is optimized, a unique excitation function is used, multi-dimensional pooling is carried out in one layer, and meanwhile orthogonal optimization is combined, so that the correlation of parameters is reduced, the network structure is more suitable for input data obtained by processing in the steps, high-precision identification can be realized under a simpler network structure, and the operation burden is reduced.
Detailed Description
Step 1: acquisition of dynamic image signals in motor operation process
The camera with the image sensor is used for mounting the camera at a position where a spark area generated in the motor can be completely shot, and the optical lens of the camera is aligned with the position of a spark line and used for collecting dynamic image signals in the running process of the motor.
The dynamic image signals are captured by two sensors capable of sensing optical signals of different wave bands and are respectively positioned in a visible light wave band and an ultraviolet wave band; sparks generated by the motor can generate stronger response in an ultraviolet band relative to a visible light band, and the detection precision is improved; and meanwhile, the visible light wave band is collected, so that the distribution position of the generated sparks can be better identified. Compared with the existing case that only a visible light detection method is adopted, the configuration can improve the detection precision and reduce the false alarm rate of faults.
The image signals collected by the visible light wave band and the ultraviolet wave band are collected in pairs according to time sequence, and the image signals collected at the same time are quantized and coded to form a visible light digital imageAnd an ultraviolet digital image>Respectively use>、And (4) showing. Each image is represented by a two-dimensional matrix. One element in the two-dimensional matrix is referred to as one pixel of the image. By usingRepresenting the coordinates of a pixel in an image, i.e. the coordinates of a matrix element, in conjunction with a pixel in the image>Respectively representing the row and column directions of the matrixSubscripts of (a).、/>Respectively represent->、/>Middle coordinate is>The pixel value of (2).
For ultraviolet digital imagePerforming pretreatment, and detecting ultraviolet digital image->The probability of motor sparking being present.
Ultraviolet digital imageAnd performing linear transformation. For convenience of mathematical expression, the subscripts of the elements of the matrix or vector in the present invention are counted from 0. Is arranged and/or is>Represents a matrix->Is the width of the image, is greater than>Is a matrix->The total number of rows of (a),i.e. the height of the image. Define >>Square matrix based on the status of the blood pressure>:/>
Is a matrix>Is selected based on the presence of>Is an element matrix->In (c), based on the coordinate of (c)>Is a matrix->The total number of rows. Is a matrix->The element assignments are:
matrix arrayAccording to the collection characteristics of the ultraviolet image and the image characteristics of the spark, the original image is based on the UV image collection characteristics and the spark image characteristics>According to >>After linear transformation, the original characteristics of the spark part are kept, noise caused by the sensor in the ultraviolet image is eliminated, and the signal-to-noise ratio of the ultraviolet image is improved.
Solving forThe value of the middle pixel is greater than the threshold value (recorded as->) If the number of pixels is larger than the threshold value (marked as) Then the spark is deemed to be present in the image, otherwise the spark is deemed to be absent. Tested preferably->(normalization of the image pixel value range to 0-1), -or (R) in the image>. In the step 1, the spark is primarily filtered through the ultraviolet image, so that the false alarm rate can be further reduced, and the detection precision is improved.
And 2, step: spark prepositioning and visible light image coordinate normalization based on ultraviolet image motor spark pre-detection
If spark exists in the collected image, the ultraviolet digital image is processedSpark pre-positioning is performed, i.e. using the following template:
WhereinIndicates that the template is->Is in the position coordinate, </or is greater than or equal to>Representing coordinates in the original>The convolution offset coordinate is the center.
The above-mentioned templateIn order to learn and obtain the ultraviolet image spark data based on a large amount of ultraviolet image spark data by adopting a Bayesian learning method, 3-by-3 median filtering is further applied to the learning result to smooth the template for the convenience of use, and the template is re-quantized according to the step value of 0.05 to obtain the result of formula 1.
For a collected ultraviolet imageBased on equation 2, calculate->And find out->Is recorded as the position of the maximum in->As an ultraviolet image->A preset point in the middle of the spark.
Will be mixed withThe corresponding visible light image->According to>Performing space translation to normalize the initial coordinates of all visible light images to the spark center position, and recording the obtained translated visible light images as:
the effect of the translation operation is to normalize the initial coordinates of all visible images to the spark center position, which helps to move the image portions of the environment that are not associated with motor sparks to the periphery of the image, and to assign a lower detection weight in the subsequent steps, which can better remove the environmental noise in the image.
And step 3: spark detection using neural networks based on coordinate normalized visible light images
And at a certain moment, acquiring a visible light image and an ultraviolet image according to the step 1, preprocessing the ultraviolet image, and judging the probability of sparks in the ultraviolet image. If the preprocessing result meets the threshold value in the step 1, continuing; otherwise, waiting for the next acquisition time.
Pre-positioning sparks in the ultraviolet image according to the step 2 to obtain the ultraviolet imageAnd (4) the coordinates of the center of the spark are obtained, and the visible light image is translated according to the coordinates to obtain a coordinate normalized visible light image.
Spark recognition is performed on the coordinate normalized visible light image according to the following steps.
Firstly, a convolution feature extraction layer is established, and local feature extraction modeling is carried out on the visible light image.
Namely:
in the above formula, the first and second carbon atoms are,is a convolution kernel of the matrix, is asserted>Is a relative coordinate in a convolution kernel, and>the visible light image is normalized for coordinates. />Is a subscript to the convolution kernel, device for selecting or keeping>Indicates the fifth->A convolution kernel, in the present invention, preferably->Has a value in the range of 0-31, i.e. there are 32 convolution kernels->、/>、/>. 32 matrix results, i.e., -corresponding to the convolutional feature extraction layer>、/>、…、。/>Is linearly biasedAmount of the compound (A). />The method is used for non-linearizing the linear convolution to realize the non-linear sample classification.
In the above formula, according to the data characteristics of the practical application of the present invention, the above nonlinear activation function is designed and the coefficients are introducedThe convergence speed of the function is adjusted, so that the recognition rate of the model to sparks is improved; />Preferably +>。
Secondly, on the basis of the convolution feature extraction layer, a multi-scale pooling layer is established, the convolution feature layer is compressed, and the calculation efficiency is improved.
Different from the common convolution pooling, the multi-scale pooling layer established by the invention also performs pooling between the convolution layers, so that the data volume is further reduced, and the calculation efficiency is improved; while further introducing pooling parameters during pooling between layers (、/>、/>、/>) The accuracy of pooling can be improved. />Is a linear offset. />As defined above.
And secondly, establishing an orthogonal optimization layer on the basis of the multi-scale pooling layer.
Wherein, the first and the second end of the pipe are connected with each other,,/>satisfies the following conditions:
spatial coordinates representing 16 groups from a three-dimensional pooling layer +>To orthogonally optimized layer>Is based on the fifth->The linear mapping of the elements and the constraint of the formula 8 enable the elements to have orthogonal characteristics, reduce the correlation between parameters and contribute to improving the modelAnd (4) detecting the capability.
Parameter(s)For normalizing data of the three-dimensional pooling layer, there are 8 matrices (m takes the value of 32/4= 8) in the three-dimensional pooling layer. />Is a linear offset. />As defined above.
Finally, the output layer is defined as the probability of detecting motor sparks:
wherein the content of the first and second substances,indicating a fifth degree of linkage with an orthogonally optimized layer>Linear mapping of elements to output layers, based on the number of pixels in a pixel>Is a linear offset. />As defined above. Output layer>Indicating a probability of detecting a motor spark, based on a motor speed and a motor speed>Approaching 0 indicates no spark detected, and>approaching 1 indicates that a spark is detected.
And (3) training the models 4-9 by adopting a Back Propagation (BP) algorithm, determining values of convolution kernels in the formula 4, pooling parameters in the formula 6, linear mapping parameters in the formulas 7 and 9 and other unknown parameter values, and finishing training.
Before training, preparing a plurality of visible light images with sparks, and after the translation normalization in the step 2, using the visible light images as positive samples, and after the translation normalization in the step 2, using the visible light images without sparks as negative samples; and inputting the sample into the model to carry out iterative computation, comparing the sample true value with the model output value in each round, and iterating until the sample true value is converged to finish training.
After the training is finished, the coordinate normalization visible light image obtained at the beginning of the step 3 can be detected by the method, and the probability estimation value is obtained through the modelIf is>Greater than a threshold value (marked>) Spark detection is determined, otherwise no spark is determined to be detected. Preferably, setting +>=0.8。
Step 4, automatic recognition and control of spark faults in the motor operation process based on image detection
And (3) acquiring images in real time according to the steps 1-3, processing, detecting the visible light images in each pair of acquired images according to the model and the method in the step 3, judging that the motor has a fault after detecting sparks, sending a stop signal to the motor, and controlling the motor to stop.
The following table is a comparison of the results of the test using the method of the present invention and the existing CNN neural network method, and it can be seen from the table that the test effect is better because the image preprocessing process of the present invention is matched with the neural network structure, and both are specially designed for motor spark detection, considering the actual application environment.
TABLE 1
The method is implemented in the following system:
the collection equipment: including ultraviolet cameras and visible light cameras.
The pretreatment equipment comprises: comprises a processor connected with the acquisition equipment and is arranged on site.
A server: and storing the trained neural network model, receiving and judging the image sent by the preprocessing equipment, and sending a control signal to the controller.
A controller: for controlling the motor action.
It will be appreciated by those skilled in the art that while a number of exemplary embodiments of the invention have been shown and described in detail herein, many other variations or modifications can be made, which are consistent with the principles of this invention, and which are directly determined or derived from the disclosure herein, without departing from the spirit and scope of the invention. Accordingly, the scope of the invention should be understood and interpreted to cover all such other variations or modifications.
Claims (10)
1. A motor operation process fault automatic identification and control method is characterized in that: collecting the electric spark image of the motor to form a visible light digital image I v And an ultraviolet digital image I u Each image is represented by a two-dimensional matrix;
phi (p, q) is an element of the matrix phi, and (p, q) is a coordinate in the element matrix phi; x represents a matrix I u The total number of columns, i.e. the width of the image, Y being the matrix I u The total number of rows of (i.e. the height of the image), defines a Y x Y square matrix Φ, the elements of which are assigned to:
Where% represents the remainder operation, χ is the matrix of 4x4 orthogonal bases:
then define H u Is matrix phi and matrix I u The product of (a):
H u =Φ×I u …(1)
solving for H u If the number of the pixels is larger than the threshold value, the spark exists in the image, otherwise, the spark does not exist;
if spark exists in the collected image, the ultraviolet digital image I is subjected to u Carrying out spark prepositioning:
wherein (i, j) represents a template T u (x + i, y + j) represents a convolution offset coordinate centered on the coordinate (x, y) in the original image;
finding R u Is (x) as the position of the maximum value 0 ,y 0 ) As an ultraviolet image I u Presetting a point in the center of the middle spark; normalizing the initial coordinates of all visible light images to the spark center position;
utilizing a neural network to carry out spark detection based on the coordinate normalized visible light image, wherein the neural network has the structure that: the method comprises a convolution characteristic extraction layer, a multi-scale pooling layer, an orthogonal optimization layer and an output layer;
wherein the multi-scale pooling layer output is:
wherein, κ 1 、κ 2 、κ 3 、κ 4 For the pooling parameter, beta 1 Is a linear offset, λ is an excitation function, Θ 4m 、Θ 4m+1 、Θ 4m+2 、Θ 4m+3 The result of the convolution feature extraction of the previous layer.
2. The method of claim 1, wherein: and after the spark is detected, judging that the motor fails, sending a stop signal to the motor, and controlling the motor to stop.
3. The method of claim 1, wherein: the model is trained using a Back Propagation (BP) algorithm.
4. The method of claim 3, wherein: and determining values of a convolution kernel, a pooling parameter and a linear mapping parameter through training to finish the training.
5. The method of claim 3, wherein: before training, a plurality of visible light images with sparks are prepared and are used as positive samples after translation normalization.
6. The method of claim 3, wherein: and a plurality of visible light images without sparks are used as negative samples after translation and normalization.
7. The method of claim 6, wherein: the positive samples give a sample truth value 1, and the negative samples give a sample truth value 0.
8. The method of claim 7, wherein: and inputting the sample into the model to carry out iterative computation, comparing the true value of the sample with the output value of the model in each round, and iterating until convergence to finish training.
9. The method of claims 1-8, wherein: including by site processors and servers.
10. The method of claim 9, wherein: the field processor carries out acquisition image preprocessing, and the server detects and identifies the preprocessed image by utilizing the neural network and sends a control signal to the controller.
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