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Abstract— Maintenance and repair of wind turbine struc- the condition of machines while in operation and involves
tures have become more challenging and at the same time the observation of the system by sampling dynamic response
essential as they evolve into larger dimensions or located in measurements from a group of sensors and the analysis of
places with limited access. Even small structural damages
may invoke catastrophic detriment to the integrity of the sys- the data to determine the current state of system health. This
tem. So, cost-effective, predictive, and reliable structural health goal is being pursued through the development of reliable
monitoring (SHM) system has been always desirable for wind sensors, and intelligent algorithms.
turbines. A real-time nondestructive SHM technique based on Although any part of the wind turbine is prone to failure [4],
multisensor data fusion is proposed in this paper. The objective considerable attention is often given to the turbine blades
is to critically analyze and evaluate the feasibility of the proposed
technique to identify and localize damages in wind turbine as they are the main elements of the system. The blades
blades. The structural properties of the turbine blade before and could cost up to 20% of the total cost and theirs are the
after damage are investigated through different sets of finite- most expensive type of damage to repair [5]. Numerous
element method simulations. Based on the obtained results, it is wind turbine blade damage detection and health monitoring
shown that information from smart sensors, measuring strains, techniques exist, each with its own advantages and drawbacks:
and vibrations data, distributed over the turbine blades can be
used to assist in more accurate damage detection and overall Acoustic emission sensors [6], ultrasonic testing [7], ther-
understanding of the health condition of blades. Data fusion mal imaging method [8], x-ray radioscopy [9], Eddy current
technique is proposed to combine these two diagnostic tools to method [10], fiber optic (FO) sensors [11], PZT patches [12],
improve the detection system that provides a more robust reading smart materials and strain memory alloy method [13], wavelet
with reduced false alarms. transforms [14], and microwave techniques [15] are the key
Index Terms— Condition monitoring, strain sensor, vibration, examples. The majority of these methods have limitations with
data fusion, microelectromechanical systems. regard to large-scale sensing, difficult signal interpretation, or
have safety issues. FO strain sensors and particularly fibre
I. I NTRODUCTION
Bragg gratings (FBGs) [16] are currently the most widely
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1438 IEEE SENSORS JOURNAL, VOL. 15, NO. 3, MARCH 2015
III. M ULTISENSOR F USION M ODEL where wk is the measurement noise (N(0, R)).
The Kalman filter estimates μk|k in a predictor/corrector
Data from individual sensors cannot be fully reliable and do algorithm [37], as shown in Fig. 2. In the prediction step, the
not provide complete information. Fusing measurements data filtered reading μk−1|k−1 and its covariance matrix k−1|k−1
from multiple sensors enables us to make inferences that are are projected to the next time step k. Therefore:
not possible through single sensors. Incorporating data fusion
into an SHM system requires the combination and integration μk|k−1 = μk−1|k−1 (3)
of different diagnostic tools to improve the detection system k|k−1 = Q + k−1|k−1 (4)
and reduce false alarms. A monitoring system using data
In the correction step we fuse the predicted values with the
fusion can be composed of any number of sensors, measuring
measurement yk :
only one or different properties of the host structure and placed
in different locations. μk|k = μk|k−1 + K k (yk − μk|k−1 ) (5)
In the case of SHM of wind turbine blades, in order to k|k = (I − K k )k|k−1 (6)
improve the prognostic forecasting of the system, sensors data
where K k = k|k−1 (k|k−1 + R) − 1 (7)
can also be combined with structural and material properties
of the blade, or even damage models. As explained in the Now, each fusion node is providing reliable mean value of the
previous section, strain fields and natural frequencies measured object property, Y, and its variance, σ .
by MEMS sensors can efficiently be used for damage detection Natural frequencies and modal properties are global proper-
and localization in wind turbine blades. Combining both ties of the structure under monitoring. So, multiple sensors are
approaches, a multisensor data fusion procedure is proposed used to determine the same property at different locations of
in this section. In addition to strain and vibration sensors, the blade. Furthermore, each sensor output contains measure-
the design includes input/output cells, data fusion nodes and ment errors and in this way sensor uncertainty can be reduced.
1440 IEEE SENSORS JOURNAL, VOL. 15, NO. 3, MARCH 2015
Fig. 3. The operation of the proposed intelligent wind turbine damage detection system. Strain and vibration sensors (Si ) send their reliable measurements
through some data fusion nodes to F1 and F2 which outputs the variables I and C. I , a number between 0 and 1, indicates damage severity and C, a confidence
variable associated with I , which can be obtained from the variances. The cell F receives (I S , C S ) and (IV , C V ) as input data and generates the decision
signal I F as output. The thresholds variables can be calculated using a history models or experiments and are regarded as external knowledge.
The output of a single sensor may be misleading and others can which is the weighted average of the sensors readings, a more
resolve the uncertainty. Hence, for vibration sensors located accurate and reliable vibration data, and Cl−1 is the inverse
at multiple locations on the blade, we should also develop covariance.
the best estimate (Rv ) out of n sensors reading mean values
Y = (Y1 , Y2 , . . . , Yn ). The simplest case of fusion for a
B. Fusion Module System Health Diagnosis
multiple sensor configuration that measures the same property
is averaging, assuming that each sensor’s measurement is The next step, as depicted in Fig. 3, is the decision algorithm
equally reliable. If sensors readings are not equally reliable, fusion node that produces information about the current blade
a weighted average can be used instead. health status in the form of two variables, I and C. Of these,
As a fusion strategy, Bayesian statistics is often used I can take up values between 0 and 1 and represents the sever-
for combining multiple sensors. Maximum likelihood is a ity of the damage, and C is a confidence variable associated
well-known Bayesian approach [38], and its estimate, Rv is with I , and can be obtained from the variances. The decision
computed such that the following be maximized: fusion node, either for strain sensors or vibration sensors,
can also use data on material properties, load history etc.,
n
referred to as external knowledge in Fig. 3, to produce accurate
p(Y |Rv ) = p(Yl |Rv ) (8)
indicators. Finally, in the last fusion node, alarm may be issued
l=1
that the blade is damaged if I S indicates unhealthy blade and
By differentiating the logarithm of the likelihood and C S shows enough confidence, or if IV indicates unhealthy
equating to zero, it can be shown that [39]: blade and C V shows enough confidence, or both. There would
n be a warning if severity indicators are below alarm threshold
Cl−1 Yl but higher than the warning threshold. This can be calculated
R̃v = l=1
n −1
(9)
l=1 Cl either using the following criteria, or by any other voting
MORADI AND SIVOTHTHAMAN: MEMS MULTISENSOR INTELLIGENT DAMAGE DETECTION 1441
Fig. 4. The generated mesh and the finite element model of the blade used
for COMSOL simulations.
Fig. 6. FEM simulation output showing the variation in stress fields of a
damaged blade model. The inset shows sudden decrease around the damage
location and increase beneath or at both corner sides of the crack.
Fig. 7. Strain in vicinity of the crack for two cases of healthy and damaged
blades. Sudden decrease of strain magnitude is detectable even at locations as
far as more than 1 m on each side of the crack. The inset graph shows strain
magnitude at the upper corner side of the crack.
TABLE I
N ATURAL F REQUENCY (H Z ) C OMPARISON B ETWEEN U NDAMAGED Fig. 8. Sensor validation and damage detection reasoning process map.
(U 1−2 ) AND D AMAGED (D 1−3 ) S TATES (P ERCENTAGE C HANGES WRT U 2
A RE S HOWN IN S QUARE B RACKETS )
D2 a worse crack (1mm wider and deeper) at the same place,
and D3 same as D1 but at a location with low stress fields,
therefore less critical. Each case is carefully simulated in
COMSOL Multiphysics® . Natural frequencies of the first ten
modes obtained for the five different scenarios are presented
in Table I. Comparing the results for U1 and U2 , it can be
seen that applied stress, due to wind load or rotation, does
not create a sensible variation in natural frequencies of the
structure. So we can deduce that different wind conditions
or rotation speeds do not cause significant frequency change.
On the other hand, the presence of damage in the structure
causes a decrease in the natural frequencies in all damage
cases (D1−3 ), with very few exceptions. Severity is higher
when the crack is bigger (D2 ) or is located at higher stressed
regions (D1 vs. D3 ). Overall, it is clear that the change is more
pronounced in severe cases which are more dangerous. This
analysis shows that monitoring the shift in natural frequencies
can be a useful tool in SHM of turbine blades.
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Princeton Univ. Press, 1976. the Ph.D. degree from the University of Paris, Paris,
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algorithms: A review,” Renew. Sustain. Energy Rev., vol. 13, no. 1, Waterloo Chapter. From 2002 to 2006, he was the
pp. 1–39, 2009. NSERC Industrial Research Associate Chair in RF-Microelectromechanical
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for a bridge structure,” Eng. Struct., vol. 27, no. 10, pp. 1488–1497, energy conversion, MEMS fabrication, microelectronic devices, nanotechnolo-
2005. gies, and health and safety of renewable energy technologies.