A Review of Early Fault Diagnosis Approaches and Their Applications in Rotating Machinery

Diagnosis of Rotor Component Shedding in Rotating Machinery: A Data-Driven Approach

The potential for rotor component shedding in rotating machinery poses significant risks, necessitating the development of an early and precise fault diagnosis technique to prevent catastrophic failures and reduce maintenance costs. This study introduces a data-driven approach to detect rotor component shedding at its inception, thereby enhancing operational safety and minimizing downtime. Utilizing frequency analysis, this research identifies harmonic amplitudes within rotor vibration data as key indicators of impending faults. The methodology employs principal component analysis (PCA) to orthogonalize and reduce the dimensionality of vibration data from rotor sensors, followed by k-fold cross-validation to select a subset of significant features, ensuring the detection algorithm's robustness and generalizability. These features are then integrated into a linear discriminant analysis (LDA) model, which serves as the diagnostic engine to predict the probability of rotor component shedding. The efficacy of the approach is demonstrated through its application to 16 industrial compressors and turbines, proving its value in providing timely fault warnings and enhancing operational reliability.

Nonlinear mechanical response analysis and convolutional neural network enabled diagnosis of single-span rotor bearing system

The wide application of rotating machinery has boosted the development of electricity and aviation, however, long-term operation can lead to a variety of faults. The use of different measures to deal with corresponding malfunctions is the key to generating benefits, so it is significant to carry out the fault diagnosis of rotating machinery. In this work, a test bench for single-span rotor bearings was established, three faults, including spindle bending, spindle crack without end loading and spindle crack with end loading, are experimental analyzed with basic mechanical response. Moreover, a diagnosis is performed using a convolutional neural network, according to the differences in mechanical responses of the three faults obtained from experiments. For three faults, the change in the properties of spindle itself results in different axis trajectories and spectra. Compared with spindle bending fault, spindle crack fault not only cause 1×, 2×, 3× frequency component excitation, also 4×, 5× frequency component excitation. Additionally, the classification accuracy of the training set and the test set under machine learning for the three types of working conditions is 100%. This indicates that the network can significantly identify signal features so as to make effective fault classification.

Deep Reconstruction Transfer Convolutional Neural Network for Rolling Bearing Fault Diagnosis

Deep transfer learning has been widely used to improve the versatility of models. In the problem of cross-domain fault diagnosis in rolling bearings, most models require that the given data have a similar distribution, which limits the diagnostic effect and generalization of the model. This paper proposes a deep reconstruction transfer convolutional neural network (DRTCNN), which satisfies the domain adaptability of the model under cross-domain conditions. Firstly, the model uses a deep reconstruction convolutional automatic encoder for feature extraction and data reconstruction. Through sharing parameters and unsupervised training, the structural information of target domain samples is effectively used to extract domain-invariant features. Secondly, a new subdomain alignment loss function is introduced to align the subdomain distribution of the source domain and the target domain, which can improve the classification accuracy by reducing the intra-class distance and increasing the inter-class distance. In addition, a label smoothing algorithm considering the credibility of the sample is introduced to train the model classifier to avoid the impact of wrong labels on the training process. Three datasets are used to verify the versatility of the model, and the results show that the model has a high accuracy and stability.

Scale-Fractal Detrended Fluctuation Analysis for Fault Diagnosis of a Centrifugal Pump and a Reciprocating Compressor

Reciprocating compressors and centrifugal pumps are rotating machines used in industry, where fault detection is crucial for avoiding unnecessary and costly downtime. A novel method for fault classification in reciprocating compressors and multi-stage centrifugal pumps is proposed. In the feature extraction stage, raw vibration signals are processed using multi-fractal detrended fluctuation analysis (MFDFA) to extract features indicative of different types of faults. Such MFDFA features enable the training of machine learning models for classifying faults. Several classical machine learning models and a deep learning model corresponding to the convolutional neural network (CNN) are compared with respect to their classification accuracy. The cross-validation results show that all models are highly accurate for classifying the 13 types of faults in the centrifugal pump, the 17 valve faults, and the 13 multi-faults in the reciprocating compressor. The random forest subspace discriminant (RFSD) and the CNN model achieved the best results using MFDFA features calculated with quadratic approximations. The proposed method is a promising approach for fault classification in reciprocating compressors and multi-stage centrifugal pumps.

A Novel Hybrid Technique Combining Improved Cepstrum Pre-Whitening and High-Pass Filtering for Effective Bearing Fault Diagnosis Using Vibration Data

Rolling element bearings (REBs) are an essential part of rotating machinery. A localised defect in a REB typically results in periodic impulses in vibration signals at bearing characteristic frequencies (BCFs), and these are widely used for bearing fault detection and diagnosis. One of the most powerful methods for BCF detection in noisy signals is envelope analysis. However, the selection of an effective band-pass filtering region presents significant challenges in moving towards automated bearing fault diagnosis due to the variable nature of the resonant frequencies present in bearing systems and rotating machinery. Cepstrum Pre-Whitening (CPW) is a technique that can effectively eliminate discrete frequency components in the signal whilst detecting the impulsive features related to the bearing defect(s). Nevertheless, CPW is ineffective for detecting incipient bearing defects with weak signatures. In this study, a novel hybrid method based on an improved CPW (ICPW) and high-pass filtering (ICPW-HPF) is developed that shows improved detection of BCFs under a wide range of conditions when compared with existing BCF detection methods, such as Fast Kurtogram (FK). Combined with machine learning techniques, this novel hybrid method provides the capability for automated bearing defect detection and diagnosis without the need for manual selection of the resonant frequencies. The results from this novel hybrid method are compared with a number of established BCF detection methods, including Fast Kurtogram (FK), on vibration signals collected from the project I2BS (An EU Clean Sky 2 project 'Integrated Intelligent Bearing Systems' collaboration between Schaeffler Technologies and the University of Southampton. Safran Aero Engines was the topic manager for this project) and those from three databases available in the public domain-Case Western Reserve University (CWRU), Intelligent Maintenance Systems (IMS) datasets, and Safran jet engine data-all of which have been widely used in studies of this kind. By calculating the Signal-to-Noise Ratio (SNR) of each case, the new method is shown to be effective for a much lower SNR (with an average of 30.21) compared with that achieved using the FK method (average of 14.4) and thus is much more effective in detecting incipient bearing faults. The results also show that it is effective in detecting a combination of several bearing faults that occur simultaneously under a wide range of bearing configurations and test conditions and without the requirement of further human intervention such as extra screening or manual selection of filters.

Active Fault Isolation for Multimode Fault Systems Based on a Set Separation Indicator

This paper considers the active fault isolation problem for a class of uncertain multimode fault systems with a high-dimensional state-space model. It has been observed that the existing approaches in the literature based on a steady-state active fault isolation method are often accompanied by a large delay in making the correct isolation decision. To reduce such fault isolation latency significantly, this paper proposes a fast online active fault isolation method based on the construction of residual transient-state reachable set and transient-state separating hyperplane. The novelty and benefit of this strategy lies in the embedding of a new component called the set separation indicator, which is designed offline to distinguish the residual transient-state reachable sets of different system configurations at any given moment. Based on the results delivered by the set separation indicator, one can determine the specific moments at which the deterministic isolation is to be implemented during online diagnostics. Meanwhile, some alternative constant inputs can also be evaluated for isolation effects to determine better auxiliary excitation signals with smaller amplitudes and more differentiated separating hyperplanes. The validity of these results is verified by both a numerical comparison and an FPGA-in-loop experiment.

Controlled Symmetry with Woods-Saxon Stochastic Resonance Enabled Weak Fault Detection

Weak fault detection with stochastic resonance (SR) is distinct from conventional approaches in that it is a nonlinear optimal signal processing to transfer noise into the signal, resulting in a higher output SNR. Owing to this special characteristic of SR, this study develops a controlled symmetry with Woods-Saxon stochastic resonance (CSwWSSR) model based on the Woods-Saxon stochastic resonance (WSSR), where each parameter of the model may be modified to vary the potential structure. Then, the potential structure of the model is investigated in this paper, along with the mathematical analysis and experimental comparison to clarify the effect of each parameter on it. The CSwWSSR is a tri-stable stochastic resonance, but differs from others in that each of its three potential wells is controlled by different parameters. Moreover, the particle swarm optimization (PSO), which can quickly find the ideal parameter matching, is introduced to attain the optimal parameters of the CSwWSSR model. Fault diagnosis of simulation signals and bearings was carried out to confirm the viability of the proposed CSwWSSR model, and the results revealed that the CSwWSSR model is superior to its constituent models.

Bearing Fault Diagnosis Method Based on Improved Singular Value Decomposition Package

The singular value decomposition package (SVDP) is often used for signal decomposition and feature extraction. At present, the general SVDP has insufficient feature extraction ability due to the two-row structure of the Hankel matrix, which leads to mode mixing. In this paper, an improved singular value decomposition packet (ISVDP) algorithm is proposed: the feature extraction ability is improved by changing the structure of the Hankel matrix, and similar signal sub-components are selected by similarity to avoid having the same frequency component signals being decomposed into different sub-signals. In this paper, the effectiveness of ISVDP is illustrated by a set of simulation signals, and it is utilized in fault diagnosis of bearing data. The results show that ISVDP can effectively suppress the model-mixing phenomenon and can extract the fault features in bearing vibration signals more accurately.

A Brief Review of Acoustic and Vibration Signal-Based Fault Detection for Belt Conveyor Idlers Using Machine Learning Models

Due to increasing demands for ensuring the safety and reliability of a system, fault detection (FD) has received considerable attention in modern industries to monitor their machines. Bulk materials are transported worldwide using belt conveyors as an essential transport system. The majority of conveyor components are monitored continuously to ensure their reliability, but idlers remain a challenge to monitor due to the large number of idlers (rollers) distributed throughout the working environment. These idlers are prone to external noises or disturbances that cause a failure in the underlying system operations. The research community has begun using machine learning (ML) to detect idler's defects to assist industries in responding to failures on time. Vibration and acoustic measurements are commonly employed to monitor the condition of idlers. However, there has been no comprehensive review of FD for belt conveyor idlers. This paper presents a recent review of acoustic and vibration signal-based fault detection for belt conveyor idlers using ML models. It also discusses major steps in the approaches, such as data collection, signal processing, feature extraction and selection, and ML model construction. Additionally, the paper provides an overview of the main components of belt conveyor systems, sources of defects in idlers, and a brief introduction to ML models. Finally, it highlights critical open challenges and provides future research directions.

A transformer model with enhanced feature learning and its application in rotating machinery diagnosis

Deep learning has become the prevailing trend of intelligent fault diagnosis for rotating machines. Compared to early-stage methods, deep learning methods use automatic feature extraction instead of manual feature design. However, conventional intelligent diagnosis models are trapped by a dilemma that simple models are unable to tackle difficult cases, while complicated models are likely to over-parameterize. In this paper, a transformer-based model, Periodic Representations for Transformers (PRT) is proposed. PRT uses a dense-overlapping split strategy to enhance the feature learning inside sequence patches. Combined with the inherent capability of capturing long range dependencies of transformer, and the further information extraction of class-attention, PRT has excellent feature extraction abilities and could capture characteristic features directly from raw vibration signals. Moreover, PRT adopts a two-stage positional encoding method to encode position information both among and inside patches, which could adapt to different input lengths. A novel inference method to use larger inference sample sizes is further proposed to improve the performance of PRT. The effectiveness of PRT is verified on two datasets, where it achieves comparable and even better accuracies than the benchmark and state-of-the-art methods. PRT has the least FLOPs among the best performing models and could be further improved by the inference strategy, reaching an accuracy near 100%.

Diagnosis of Multiple Faults in Rotating Machinery Using Ensemble Learning

Fault diagnosis of rotating machines is an important task to prevent machinery downtime, and provide verifiable support for condition-based maintenance (CBM) decision-making. Deep learning-enabled fault diagnosis operations have become increasingly popular because features are extracted and selected automatically. However, it is challenging for these models to give superior results with rotating machine components of different scales, single and multiple faults across different rotating components, diverse operating speeds, and diverse load conditions. To address these challenges, this paper proposes a comprehensive learning approach with optimized signal processing transforms for single as well as multiple faults diagnosis across dissimilar rotating machine components: gearbox, bearing, and shaft. The optimized bicoherence, spectral kurtosis and cyclic spectral coherence feature spaces, and deep blending ensemble learning are explored for multiple faults diagnosis of these components. The performance analysis of the proposed approach has been demonstrated through a single joint training of the entire framework on a compound dataset containing multiple faults derived from three public repositories. A comparison with the state-of-the-art approaches that used these datasets, shows that our method gives improved results with different components and faults with nominal retraining.

Wheel-Rail Contact-Induced Impact Vibration Analysis for Switch Rails Based on the VMD-SS Method

When trains pass through damaged switch rails, rail head damage will change wheel-rail contact states from rolling frictions to unsteady contacts, which will result in impact vibrations and threaten structural safeties. In addition, under approaching and moving away rolling contact excitations and complex wheel-rail contacts, the non-stationary vibrations make it difficult to extract and analyze impact vibrations. In view of the above problems, this paper proposes a variational-mode-decomposition (VMD)-spectral-subtraction (SS)-based impact vibration extraction method. Firstly, the time domain feature analysis method is applied to calculate the time moments that the wheels pass joints, and to correct vehicle velocities. This can help estimate and confine impact vibration distribution ranges. Then, the stationary intrinsic mode function (IMF) components of the impact vibration are decomposed and analyzed with the VMD method. Finally, impact vibrations are further filtered with the SS method. For rail head damage with different dimensions, under different velocity experiments, the frequency and amplitude features of the impact vibrations are analyzed. Experimental results show that, in low-velocity scenarios, the proposed VMD-SS-based method can extract impact vibrations, the frequency features are mainly concentrated in 3500-5000 Hz, and the frequency and peak-to-peak features increase with the increase in excitation velocities.

Performance of Bearing Ball Defect Classification Based on the Fusion of Selected Statistical Features

Among the existing bearing faults, ball ones are known to be the most difficult to detect and classify. In this work, we propose a diagnosis methodology for these incipient faults' classification using time series of vibration signals and their decomposition. Firstly, the vibration signals were decomposed using empirical mode decomposition (EMD). Time series of intrinsic mode functions (IMFs) were then obtained. Through analysing the energy content and the components' sensitivity to the operating point variation, only the most relevant IMFs were retained. Secondly, a statistical analysis based on statistical moments and the Kullback-Leibler divergence (KLD) was computed allowing the extraction of the most relevant and sensitive features for the fault information. Thirdly, these features were used as inputs for the statistical clustering techniques to perform the classification. In the framework of this paper, the efficiency of several family of techniques were investigated and compared including linear, kernel-based nonlinear, systematic deterministic tree-based, and probabilistic techniques. The methodology's performance was evaluated through the training accuracy rate (TrA), testing accuracy rate (TsA), training time (Trt) and testing time (Tst). The diagnosis methodology has been applied to the Case Western Reserve University (CWRU) dataset. Using our proposed method, the initial EMD decomposition into eighteen IMFs was reduced to four and the most relevant features identified via the IMFs' variance and the KLD were extracted. Classification results showed that the linear classifiers were inefficient, and that kernel or data-mining classifiers achieved 100% classification rates through the feature fusion. For comparison purposes, our proposed method demonstrated a certain superiority over the multiscale permutation entropy. Finally, the results also showed that the training and testing times for all the classifiers were lower than 2 s, and 0.2 s, respectively, and thus compatible with real-time applications.

A Multi-Scale and Lightweight Bearing Fault Diagnosis Model with Small Samples

Currently, deep-learning-based methods have been widely used in fault diagnosis to improve the diagnosis efficiency and intelligence. However, most schemes require a great deal of labeled data and many iterations for training parameters. They suffer from low accuracy and over fitting under the few-shot scenario. In addition, a large number of parameters in the model consumes high computing resources, which is far from practical. In this paper, a multi-scale and lightweight Siamese network architecture is proposed for the fault diagnosis with few samples. The architecture proposed contains two main modules. The first part implements the feature vector extraction of sample pairs. It is composed of two lightweight convolutional networks with shared weights symmetrically. Multi-scale convolutional kernels and dimensionality reduction are used in these two symmetric networks to improve feature extraction and reduce the total number of model parameters. The second part takes charge of calculating the similarity of two feature vectors to achieve fault classification. The proposed network is validated by multiple datasets with different loads and speeds. The results show that the model has better accuracy, fewer model parameters and a scale compared to the baseline approach through our experiments. Furthermore, the model is also proven to have good generalization capability.

Hierarchical Amplitude-Aware Permutation Entropy-Based Fault Feature Extraction Method for Rolling Bearings

In order to detect the incipient fault of rolling bearings and to effectively identify fault characteristics, based on amplitude-aware permutation entropy (AAPE), an enhanced method named hierarchical amplitude-aware permutation entropy (HAAPE) is proposed in this paper to solve complex time series in a new dynamic change analysis. Firstly, hierarchical analysis and AAPE are combined to excavate multilevel fault information, both low-frequency and high-frequency components of the abnormal bearing vibration signal. Secondly, from the experimental analysis, it is found that HAAPE is sensitive to the early failure of rolling bearings, which makes it suitable to evaluate the performance degradation of a bearing in its run-to-failure life cycle. Finally, a fault feature selection strategy based on HAAPE is put forward to select the bearing fault characteristics after the application of the least common multiple in singular value decomposition (LCM-SVD) method to the fault vibration signal. Moreover, several other entropy-based methods are also introduced for a comparative analysis of the experimental data, and the results demonstrate that HAAPE can extract fault features more effectively and with a higher accuracy.

Latent Dimensions of Auto-Encoder as Robust Features for Inter-Conditional Bearing Fault Diagnosis

Condition-based maintenance (CBM) is becoming a necessity in modern manufacturing units. Particular focus is given to predicting bearing conditions as they are known to be the major reason for machine down time. With the open-source availability of different datasets from various sources and certain data-driven models, the research community has achieved good results for diagnosing faults in bearing fault datasets. However, existing data-driven fault diagnosis methods do not focus on the changing conditions of a machine or assume all conditional data are available all the time. In reality, conditions vary over time. This variability can be based on the measurement noise and operating conditions of the monitored machines such as radial load, axial load, rotation speed, etc. Moreover, the availability of the data measured in varying operating conditions is scarce, as it is not always feasible to collect in-process data in every possible condition or setting. Considering such a scenario, it is necessary to develop methodologies that are robust to conditional variability, i.e., methodologies to transfer the learning from one condition to another without prior knowledge of the variability. This paper proposes the usage of latent values of an auto-encoder as robust features for inter-conditional fault classification. The proposed robust classification method MLCAE-KNN is implemented in three steps. First, the time series data are transformed using Fast Fourier Transform. Using the transformed data of any one condition, a Multi-Layer Convolutional Auto-Encoder (MLCAE) is trained. Next, a K-Nearest Neighbors (KNN) classifier is trained based on the latent features of MLCAE. The so-trained MLCAE-KNN is then used to predict the fault class of any new observation from a new condition. The results of using the latent features of the Auto-Encoder show superior inter-conditional classification robustness and superior accuracies compared to the state-of-the-art.

Fault Detection of Bearing: An Unsupervised Machine Learning Approach Exploiting Feature Extraction and Dimensionality Reduction

The monitoring of rotating machinery is an essential activity for asset management today. Due to the large amount of monitored equipment, analyzing all the collected signals/features becomes an arduous task, leading the specialist to rely often on general alarms, which in turn can compromise the accuracy of the diagnosis. In order to make monitoring more intelligent, several machine learning techniques have been proposed to reduce the dimension of the input data and also to analyze it. This paper, therefore, aims to compare the use of vibration features extracted based on machine learning models, expert domain, and other signal processing approaches for identifying bearing faults (anomalies) using machine learning (ML)—in addition to verifying the possibility of reducing the number of monitored features, and consequently the behavior of the model when working with reduced dimensionality of the input data. As vibration analysis is one of the predictive techniques that present better results in the monitoring of rotating machinery, vibration signals from an experimental bearing dataset were used. The proposed features were used as input to an unsupervised anomaly detection model (Isolation Forest) to identify bearing fault. Through the study, it is possible to verify how the ML model behaves in view of the different possibilities of input features used, and their influences on the final result in addition to the possibility of reducing the number of features that are usually monitored by reducing the dimension. In addition to increasing the accuracy of the model when extracting correct features for the application under study, the reduction in dimensionality allows the specialist to monitor in a compact way the various features collected on the equipment.

Feature-Based Multi-Class Classification and Novelty Detection for Fault Diagnosis of Industrial Machinery

Given the strategic role that maintenance assumes in achieving profitability and competitiveness, many industries are dedicating many efforts and resources to improve their maintenance approaches. The concept of the Smart Factory and the possibility of highly connected plants enable the collection of massive data that allow equipment to be monitored continuously and real-time feedback on their health status. The main issue met by industries is the lack of data corresponding to faulty conditions, due to environmental and safety issues that failed machinery might cause, besides the production loss and product quality issues. In this paper, a complete and easy-to-implement procedure for streaming fault diagnosis and novelty detection, using different Machine Learning techniques, is applied to an industrial machinery sub-system. The paper aims to offer useful guidelines to practitioners to choose the best solution for their systems, including a model hyperparameter optimization technique that supports the choice of the best model. Results indicate that the methodology is easy, fast, and accurate. Few training data guarantee a high accuracy and a high generalization ability of the classification models, while the integration of a classifier and an anomaly detector reduces the number of false alarms and the computational time.

Data-Driven Deep Learning-Based Attention Mechanism for Remaining Useful Life Prediction: Case Study Application to Turbofan Engine Analysis

Accurately predicting the remaining useful life (RUL) of the turbofan engine is of great significance for improving the reliability and safety of the engine system. Due to the high dimension and complex features of sensor data in RUL prediction, this paper proposes four data-driven prognostic models based on deep neural networks (DNNs) with an attention mechanism. To improve DNN feature extraction, data are prepared using a sliding time window technique. The raw data collected after normalizing is simply fed into the suggested network, requiring no prior knowledge of prognostics or signal processing and simplifying the proposed method’s applicability. In order to verify the RUL prediction ability of the proposed DNN techniques, the C-MAPSS benchmark dataset of the turbofan engine system is validated. The experimental results showed that the developed long short-term memory (LSTM) model with attention mechanism achieved accurate RUL prediction in both scenarios with a high degree of robustness and generalization ability. Furthermore, the proposed model performance outperforms several state-of-the-art prognosis methods, where the LSTM-based model with attention mechanism achieved an RMSE of 12.87 and 11.23 for FD002 and FD003 subset of data, respectively.

Acoustic Anomaly Detection of Mechanical Failures in Noisy Real-Life Factory Environments

Anomaly detection without employing dedicated sensors for each industrial machine is recognized as one of the essential techniques for preventive maintenance and is especially important for factories with low automatization levels, a number of which remain much larger than autonomous manufacturing lines. We have based our research on the hypothesis that real-life sound data from working industrial machines can be used for machine diagnostics. However, the sound data can be contaminated and drowned out by typical factory environmental sound, making the application of sound data-based anomaly detection an overly complicated process and, thus, the main problem we are solving with our approach. In this paper, we present a noise-tolerant deep learning-based methodology for real-life sound-data-based anomaly detection within real-world industrial machinery sound data. The main element of the proposed methodology is a generative adversarial network (GAN) used for the reconstruction of sound signal reconstruction and the detection of anomalies. The experimental results obtained in the Malfunctioning Industrial Machine Investigation and Inspection (MIMII) show the superiority of the proposed methodology over baseline approaches based on the One-Class Support Vector Machine (OC-SVM) and the Autoencoder–Decoder neural network. The proposed schematics using the unscented Kalman Filter (UKF) and the mean square error (MSE) loss function with the L2 regularization term showed an improvement of the Area Under Curve (AUC) for the noisy pump data of the pump.

Bearing Fault Feature Extraction and Fault Diagnosis Method Based on Feature Fusion

Bearing is one of the most important parts of rotating machinery with high failure rate, and its working state directly affects the performance of the entire equipment. Hence, it is of great significance to diagnose bearing faults, which can contribute to guaranteeing running stability and maintenance, thus promoting production efficiency and economic benefits. Usually, the bearing fault features are difficult to extract effectively, which results in low diagnosis performance. To solve the problem, this paper proposes a bearing fault feature extraction method and it establishes a bearing fault diagnosis method that is based on feature fusion. The basic idea of the method is as follows: firstly, the time-frequency feature of the bearing signal is extracted through Wavelet Packet Transform (WPT) to form the time-frequency characteristic matrix of the signal; secondly, the Multi-Weight Singular Value Decomposition (MWSVD) is constructed by singular value contribution rate and entropy weight. The features of the time-frequency feature matrix obtained by WPT are further extracted, and the features that are sensitive to fault in the time-frequency feature matrix are retained while the insensitive features are removed; finally, the extracted feature matrix is used as the input of the Support Vector Machine (SVM) classifier for bearing fault diagnosis. The proposed method is validated by data sets from the time-varying bearing data from the University of Ottawa and Case Western Reserve University Bearing Data Center. The results show that the algorithm can effectively diagnose the bearing under the steady-state and unsteady state. This paper proposes that the algorithm has better fault diagnosis capabilities and feature extraction capabilities when compared with methods that aree based on traditional feature technology.

Belt Conveyors Rollers Diagnostics Based on Acoustic Signal Collected Using Autonomous Legged Inspection Robot

Growing demand for raw materials forces mining companies to reach deeper deposits. Difficult environmental conditions, especially high temperature and the presence of toxic/explosives gases, as well as high seismic activity in deeply located areas, pose serious threats to humans. In such conditions, running an exploration strategy of machinery parks becomes a difficult challenge, especially from the point of view of technical facilities inspections performed by mining staff. Therefore, there is a growing need for new, reliable, and autonomous inspection solutions for mining infrastructure, which will limit the role of people in these areas. In this article, a method for detection of conveyor rollers failure based on an acoustic signal is described. The data were collected using an ANYmal autonomous legged robot inspecting conveyors operating at the Polish Ore Enrichment Plant of KGHM Polska Miedź S.A., a global producer of copper and silver. As a part of an experiment, about 100 m of operating belt conveyor were inspected. The sound-based fault detection in the plant conditions is not a trivial task, given a considerable level of sonic disturbance produced by a plurality of sources. Additionally, some disturbances partially coincide with the studied phenomenon. Therefore, a suitable filtering method was proposed. Developed diagnostic algorithms, as well as ANYmal robot inspection functionalities and resistance to underground conditions, are developed as a part of the “THING–subTerranean Haptic INvestiGator” project.

Deep learning algorithms for rotating machinery intelligent diagnosis: An open source benchmark study

Rotating machinery intelligent diagnosis based on deep learning (DL) has gone through tremendous progress, which can help reduce costly breakdowns. However, different datasets and hyper-parameters are recommended to be used, and few open source codes are publicly available, resulting in unfair comparisons and ineffective improvement. To address these issues, we perform a comprehensive evaluation of four models, including multi-layer perception (MLP), auto-encoder (AE), convolutional neural network (CNN), and recurrent neural network (RNN), with seven datasets to provide a benchmark study. We first gather nine publicly available datasets and give a comprehensive benchmark study of DL-based models with two data split strategies, five input formats, three normalization methods, and four augmentation methods. Second, we integrate the whole evaluation codes into a code library and release it to the public for better comparisons. Third, we use specific-designed cases to point out the existing issues, including class imbalance, generalization ability, interpretability, few-shot learning, and model selection. Finally, we release a unified code framework for comparing and testing models fairly and quickly, emphasize the importance of open source codes, provide the baseline accuracy (a lower bound), and discuss existing issues in this field. The code library is available at: https://github.com/ZhaoZhibin/DL-based-Intelligent-Diagnosis-Benchmark.

A New Effective Method of Induction Machine Condition Assessment Based on Zero-Sequence Voltage (ZSV) Symptoms

Non-invasive diagnostic methods for electric machines’ diagnostics, which can be used during their operation in a drive system, are needed in many branches of the production industry. For the reliable condition assessment of electric machines, especially those operating in drive systems, various tools and methods have been suggested. One diagnostic method that has not been fully recognized and documented is a diagnostic method based on zero-sequence voltage component (ZSV) applications for the condition assessment of induction machines. In this paper, the application of ZSV in induction machine diagnostics is proposed. A factor that speaks in favor of applying this signal in such diagnostics is the high sensitivity of the signal to damage occurrence, and the distinct change of extracted symptoms in the case of asymmetry. It is possible to obtain a high signal amplitude, which simplifies its processing and the elaboration of reliable diagnostic factors. This ZSV-based method is also able to be applied to big machines used in industry. Due to the saturation effects visible in the ZSV signal, new diagnostic symptoms can appear, which allows for an easier condition assessment of certain machines. The usefulness of the described diagnostic method in machine condition assessment was shown through an equivalent circuit modeling process, finite element analysis, and laboratory tests of the machine.

Rope Tension Fault Diagnosis in Hoisting Systems Based on Vibration Signals Using EEMD, Improved Permutation Entropy, and PSO-SVM

Fault diagnosis of rope tension is significantly important for hoisting safety, especially in mine hoists. Conventional diagnosis methods based on force sensors face some challenges regarding sensor installation, data transmission, safety, and reliability in harsh mine environments. In this paper, a novel fault diagnosis method for rope tension based on the vibration signals of head sheaves is proposed. First, the vibration signal is decomposed into some intrinsic mode functions (IMFs) by the ensemble empirical mode decomposition (EEMD) method. Second, a sensitivity index is proposed to extract the main IMFs, then the de-noised signal is obtained by the sum of the main IMFs. Third, the energy and the proposed improved permutation entropy (IPE) values of the main IMFs and the de-noised signal are calculated to create the feature vectors. The IPE is proposed to improve the PE by adding the amplitude information, and it proved to be more sensitive in simulations of impulse detecting and signal segmentation. Fourth, vibration samples in different tension states are used to train a particle swarm optimization–support vector machine (PSO-SVM) model. Lastly, the trained model is implemented to detect tension faults in practice. Two experimental results validated the effectiveness of the proposed method to detect tension faults, such as overload, underload, and imbalance, in both single-rope and multi-rope hoists. This study provides a new perspective for detecting tension faults in hoisting systems.

Multi-Channel Real-Time Condition Monitoring System Based on Wideband Vibration Analysis of Motor Shafts Using SAW RFID Tags Coupled with Sensors

While there is a wide range of approaches to monitor industrial machinery through their static components, rotating components are usually harder to monitor, since sensors are difficult to be mounted on them and continuously read during operation. However, the characteristics of rotating components may provide useful information about the machine condition to be included in monitoring algorithms, specially for long-term data analysis. In this work, wireless vibration monitoring of rotating machine parts is investigated using surface acoustic wave (SAW) radio frequency identification (RFID) tags coupled with sensors. The proposed augmented transponder solution, combined with low-latency interrogation and signal processing, enables real-time identification and wideband vibration sensing. On top of that, a multi-channel interrogation approach is used to compensate motion effects. This approach enhances the signal-to-noise ratio of low-power high-frequency components present on the vibration signatures and enables discriminant information extraction from rotating machine parts. Final feasibility is evaluated with induction motors and vibration measurements on rotating shafts are verified. In addition, a condition classification algorithm is implemented in an experimental setup based on different motor states. The results of this work open the possibility to feed predictive maintenance algorithms using new features extracted in real-time from wideband vibration measurements on rotating components.

Signal Denoising Method Using AIC-SVD and Its Application to Micro-Vibration in Reaction Wheels

To suppress noise in signals, a denoising method called AIC-SVD is proposed on the basis of the singular value decomposition (SVD) and the Akaike information criterion (AIC). First, the Hankel matrix is chosen as the trajectory matrix of the signals, and its optimal number of rows and columns is selected according to the maximum energy of the singular values. On the basis of the improved AIC, the valid order of the optimal matrix is determined for the vibration signals mixed with Gaussian white noise and colored noise. Subsequently, the denoised signals are reconstructed by inverse operation of SVD and the averaging method. To verify the effectiveness of AIC-SVD, it is compared with wavelet threshold denoising (WTD) and empirical mode decomposition with Savitzky-Golay filter (EMD-SG). Furthermore, a comprehensive indicator of denoising (CID) is introduced to describe the denoising performance. The results show that the denoising effect of AIC-SVD is significantly better than those of WTD and EMD-SG. On applying AIC-SVD to the micro-vibration signals of reaction wheels, the weak harmonic parameters can be successfully extracted during pre-processing. The proposed method is self-adaptable and robust while avoiding the occurrence of over-denoising.

Related Entropy Theories Application in Condition Monitoring of Rotating Machineries

Rotating machinery plays an important role in various kinds of industrial engineering. How to assess their conditions is a key problem for operating safety and condition-based maintenance. The potential anomaly, fault and failure information can be obtained by analyzing the collected condition monitoring data of the previously deployed sensors in rotating machinery. Among the available methods of analyzing sensors data, entropy and its variants can provide quantitative information contained in these sensing data. For implementing fault detection, diagnosis, and prognostics, this information can be utilized for feature extraction and selecting appropriate training data for machine learning methods. This article aims to review the related entropy theories which have been applied for condition monitoring of rotating machinery. This review consists of typical entropy theories presentation, application, summary, and discussion.

Fault Diagnosis for Rail Vehicle Axle-Box Bearings Based on Energy Feature Reconstruction and Composite Multiscale Permutation Entropy

The fault response signals of an axle-box bearing of a rail vehicle have strongly non-linear and non-stationary characteristics, which can reflect the operating state of the running gears. This paper proposes a novel method for bearing fault diagnosis based on frequency-domain energy feature reconstruction (EFR) and composite multiscale permutation entropy (CMPE). First, a wavelet packet transform (WPT) is applied to decompose the vibration signals into multiple frequency bands. Then, considering that the bearing-localized defects cause the axle-box bearing system to resonate at a high frequency, which will lead to uneven energy distribution of the signal in the frequency domain, the energy factors of each frequency band are calculated by an energy feature extraction algorithm, from which the frequency band with maximum energy factor (which contains abundant fault information) is reconstructed to the time-domain signal. Next, the complexity of the reconstructed signals is calculated by CMPE as fault feature vectors. Finally, the feature vectors are input into a medium Gaussian support vector machine (MG-SVM) for bearing condition classification. The proposed method is validated by a public bearing data set and a wheelset-bearing system test bench data set. The experimental results indicate that the proposed method can effectively extract bearing fault features and provides a new solution for condition monitoring and fault diagnosis of rail vehicle axle-box bearings.