Multi-Sensor Data Fusion Using a Relevance Vector Machine Based on an Ant Colony for Gearbox Fault Detection

A Snapshot-Stacked Ensemble and Optimization Approach for Vehicle Breakdown Prediction

Predicting breakdowns is becoming one of the main goals for vehicle manufacturers so as to better allocate resources, and to reduce costs and safety issues. At the core of the utilization of vehicle sensors is the fact that early detection of anomalies facilitates the prediction of potential breakdown issues, which, if otherwise undetected, could lead to breakdowns and warranty claims. However, the making of such predictions is too complex a challenge to solve using simple predictive models. The strength of heuristic optimization techniques in solving np-hard problems, and the recent success of ensemble approaches to various modeling problems, motivated us to investigate a hybrid optimization- and ensemble-based approach to tackle the complex task. In this study, we propose a snapshot-stacked ensemble deep neural network (SSED) approach to predict vehicle claims (in this study, we refer to a claim as being a breakdown or a fault) by considering vehicle operational life records. The approach includes three main modules: Data pre-processing, Dimensionality Reduction, and Ensemble Learning. The first module is developed to run a set of practices to integrate various sources of data, extract hidden information and segment the data into different time windows. In the second module, the most informative measurements to represent vehicle usage are selected through an adapted heuristic optimization approach. Finally, in the last module, the ensemble machine learning approach utilizes the selected measurements to map the vehicle usage to the breakdowns for the prediction. The proposed approach integrates, and uses, the following two sources of data, collected from thousands of heavy-duty trucks: Logged Vehicle Data (LVD) and Warranty Claim Data (WCD). The experimental results confirm the proposed system's effectiveness in predicting vehicle breakdowns. By adapting the optimization and snapshot-stacked ensemble deep networks, we demonstrate how sensor data, in the form of vehicle usage history, contributes to claim predictions. The experimental evaluation of the system on other application domains also indicated the generality of the proposed approach.

Multi-Sensor Fault Diagnosis Based on Time Series in an Intelligent Mechanical System

Intelligent mechanical systems are a focused area nowadays. One of the requirements of intelligent mechanical systems is to achieve intelligent fault diagnosis through the real-time acquisition and analysis of data from various sensors installed on mechanical components. In this paper, a new fault diagnosis method is proposed to solve the problems of difficulty in integrating the fault diagnosis algorithm and locating fault parts due to the complexity of modern mechanical systems. The complexity of modern industrial intelligent systems is due to the fact that the systems are composed of multiple components and there are various connections between them. Common fault diagnosis is to design specialized fault identification algorithms for the physical characteristics of each component, and the integration of different algorithms is a major challenge for system performance. Therefore, this paper investigates a general algorithm for the fault diagnosis of complex systems using the timing characteristics of sensors and transfer entropy. The fault diagnosis algorithm is based on the prediction of multi-dimensional long time series using Autoformer, and fault identification is performed based on the deviation of the predicted value from the actual value. After fault identification, a root cause analysis method of faults based on transfer entropy is proposed. The method can locate the component where the fault occurs more accurately based on the analysis of the cause-effect relationship of each component and help maintenance personnel to troubleshoot the fault.

Fault Diagnosis Method Based on Time Series in Autonomous Unmanned System

There are various types of autonomous unmanned systems, covering different spaces of sea, land, and air, and they are comprehensively going deep into multiple fields of national security and social life. Due to the development of technology, the scale of unmanned systems is getting larger and larger, the number of components in the system is increasing, and the operating environment of the system is also becoming more and more complex. Therefore, the probability of failure of the components of the system will also be significantly increased. In order to eliminate the impact of the fault in time, the fault diagnosis method is significant. Considering the differences of components in autonomous unmanned systems, if a specific fault diagnosis algorithm is designed for each type of component, it will bring difficulties to the coordinated control of the system. Therefore, this paper analyzes the data characteristics of unmanned autonomous system devices (such as sensors) and finds that these data have time series. Therefore, the data of different devices can be converted into time series, and a general fault diagnosis algorithm suitable for most devices can be studied. The fault diagnosis algorithm is based on the clustering algorithm. In order to improve the clustering effect, the time series of different devices are represented by Gaussian mixture clustering to reduce the computational complexity of the clustering calculation. Then, a time series similarity measurement method based on the improved Markov chain is proposed. This method can better distinguish normal samples from abnormal samples so as to classify and identify faults effectively.

A Deep Learning Model for Fault Diagnosis with a Deep Neural Network and Feature Fusion on Multi-Channel Sensory Signals

Collecting multi-channel sensory signals is a feasible way to enhance performance in the diagnosis of mechanical equipment. In this article, a deep learning method combined with feature fusion on multi-channel sensory signals is proposed. First, a deep neural network (DNN) made up of auto-encoders is adopted to adaptively learn representative features from sensory signal and approximate non-linear relation between symptoms and fault modes. Then, Locality Preserving Projection (LPP) is utilized in the fusion of features extracted from multi-channel sensory signals. Finally, a novel diagnostic model based on multiple DNNs (MDNNs) and softmax is constructed with the input of fused deep features. The proposed method is verified in intelligent failure recognition for automobile final drive to evaluate its performance. A set of contrastive analyses of several intelligent models based on the Back-Propagation Neural Network (BPNN), Support Vector Machine (SVM) and the proposed deep architecture with single sensory signal and multi-channel sensory signals is implemented. The proposed deep architecture of feature extraction and feature fusion on multi-channel sensory signals can effectively recognize the fault patterns of final drive with the best diagnostic accuracy of 95.84%. The results confirm that the proposed method is more robust and effective than other comparative methods in the contrastive experiments.

Fault Diagnosis for Rotating Machinery Using Multiscale Permutation Entropy and Convolutional Neural Networks

In view of the limitations of existing rotating machine fault diagnosis methods in single-scale signal analysis, a fault diagnosis method based on multi-scale permutation entropy (MPE) and multi-channel fusion convolutional neural networks (MCFCNN) is proposed. First, MPE quantitatively analyzes the vibration signals of rotating machine at different scales, and obtains permutation entropy (PE) to construct feature vector sets. Then, considering the structure and spatial information between different sensor measurement points, MCFCNN constructs multiple channels in the input layer according to the number of sensors, and each channel corresponds to the MPE feature sets of different monitored points. MCFCNN uses convolutional kernels to learn the features of each channel in an unsupervised way, and fuses the features of each channel into a new feature map. At last, multi-layer perceptron is applied to fuse multi-channel features and identify faults. Through the health monitoring experiment of planetary gearbox and rolling bearing, and compared with single channel convolutional neural networks (CNN) and existing CNN based fusion methods, the proposed method based on MPE and MCFCNN model can diagnose faults with high accuracy, stability, and speed.

State-Degradation-Oriented Fault Diagnosis for High-Speed Train Running Gears System

As one of the critical components of high-speed trains, the running gears system directly affects the operation performance of the train. This paper proposes a state-degradation-oriented method for fault diagnosis of an actual running gears system based on the Wiener state degradation process and multi-sensor filtering. First of all, for the given measurements of the high-speed train, this paper considers the information acquisition and transfer characteristics of composite sensors, which establish a distributed topology for axle box bearing. Secondly, a distributed filtering is built based on the bilinear system model, and the gain parameters of the filter are designed to minimize the mean square error. For a better presentation of the degradation characteristics in actual operation, this paper constructs an improved nonlinear model. Finally, threshold is determined based on the Chebyshev’s inequality for a reliable fault diagnosis. Open datasets of rotating machinery bearings and the real measurements are utilized in the case studies to demonstrate the effectiveness of the proposed method. Results obtained in this paper are consistent with the actual situation, which validate the proposed methods.

Research on Mechanical Fault Prediction Method Based on Multifeature Fusion of Vibration Sensing Data

Vibration sensing data is an important resource for mechanical fault prediction, which is widely used in the industrial sector. Artificial neural networks (ANNs) are important tools for classifying vibration sensing data. However, their basic structures and hyperparameters must be manually adjusted, which results in the prediction accuracy easily falling into the local optimum. For data with high levels of uncertainty, it is difficult for an ANN to obtain correct prediction results. Therefore, we propose a multifeature fusion model based on Dempster-Shafer evidence theory combined with a particle swarm optimization algorithm and artificial neural network (PSO-ANN). The model first used the particle swarm optimization algorithm to optimize the structure and hyperparameters of the ANN, thereby improving its prediction accuracy. Then, the prediction error data of the multifeature fusion using a PSO-ANN is repredicted using multiple PSO-ANNs with different single feature training to obtain new prediction results. Finally, the Dempster-Shafer evidence theory was applied to the decision-level fusion of the new prediction results preprocessed with prediction accuracy and belief entropy, thus improving the model's ability to process uncertain data. The experimental results indicated that compared to the K-nearest neighbor method, support vector machine, and long short-term memory neural networks, the proposed model can effectively improve the accuracy of fault prediction.

Faults and Diagnosis Methods of Permanent Magnet Synchronous Motors: A Review

Permanent magnet synchronous motors (PMSM) have been used in a lot of industrial fields. In this paper, a review of faults and diagnosis methods of PMSM is presented. Firstly, the electrical, mechanical and magnetic faults of the permanent magnet synchronous motor are introduced. Next, common fault diagnosis methods, such as model-based fault diagnosis, different signal processing methods, and data-driven diagnostic algorithms are enumerated. The research summarized in this paper mainly includes fault performance, harmonic characteristics, different time-frequency analysis techniques, intelligent diagnosis algorithms proposed recently and so on.

Sensors Information Fusion System with Fault Detection Based on Multi-Manifold Regularization Neighborhood Preserving Embedding

Electrical drive systems play an increasingly important role in high-speed trains. The whole system is equipped with sensors that support complicated information fusion, which means the performance around this system ought to be monitored especially during incipient changes. In such situation, it is crucial to distinguish faulty state from observed normal state because of the dire consequences closed-loop faults might bring. In this research, an optimal neighborhood preserving embedding (NPE) method called multi-manifold regularization NPE (MMRNPE) is proposed to detect various faults in an electrical drive sensor information fusion system. By taking locality preserving embedding into account, the proposed methodology extends the united application of Euclidean distance of both designated points and paired points, which guarantees the access to both local and global sensor information. Meanwhile, this structure fuses several manifolds to extract their own features. In addition, parameters are allocated in diverse manifolds to seek an optimal combination of manifolds while entropy of information with parameters is also selected to avoid the overweight of single manifold. Moreover, an experimental test based on the platform was built to validate the MMRNPE approach and demonstrate the effectiveness of the fault detection. Results and observations show that the proposed MMRNPE offers a better fault detection representation in comparison with NPE.

Research on a Mixed Gas Recognition and Concentration Detection Algorithm Based on a Metal Oxide Semiconductor Olfactory System Sensor Array

As a typical machine olfactory system index, the accuracy of hybrid gas identification and concentration detection is low. This paper proposes a novel hybrid gas identification and concentration detection method. In this method, Kernel Principal Component Analysis (KPCA) is employed to extract the nonlinear mixed gas characteristics of different components, and then K-nearest neighbour algorithm (KNN) classification modelling is utilized to realize the recognition of the target gas. In addition, this method adopts a multivariable relevance vector machine (MVRVM) to regress the multi-input nonlinear signal to realize the detection of the concentration of the hybrid gas. The proposed method is validated by using CO and CH₄ as the experimental system samples. The experimental results illustrate that the accuracy of the proposed method reaches 98.33%, which is 5.83% and 14.16% higher than that of principal component analysis (PCA) and independent component analysis (ICA), respectively. For the hybrid gas concentration detection method, the CO and CH₄ concentration detection average relative errors are reduced to 5.58% and 5.38%, respectively.

Application of an Improved Multipoint Optimal Minimum Entropy Deconvolution Adjusted for Gearbox Composite Fault Diagnosis

The fault feature extraction of gearbox is difficult to achieve under complex working conditions, and this paper presents a hybrid fault diagnosis method for gearbox based on the combining product function (CPF) and multipoint optimal minimum entropy deconvolution adjusted (MOMEDA) methods. First, ensemble local mean decomposition (ELMD) is utilized to reduce the noise in original signal, and get a series of product functions (PFs), through the correlation coefficient method to remove false components and residual components. Then, multi-point kurtosis of the definition is achieved by calculating the multi-point kurtosis spectrum of each layer PF, and the fault feature period is extracted and the PFs without periodic impact are removed. After that, in order to maintain the integrity of the original signal, the PFs with the same period are recombined by the combined product function method. Finally, the different cycle interval is configured, reduce the noise through MOMEDA on the combined signal, to further extract the fault feature. The method is applied to the feature extraction of gear box composite fault to verify the feasibility of this method.

Multi-Fault Diagnosis of Gearbox Based on Improved Multipoint Optimal Minimum Entropy Deconvolution

Under complicated conditions, the extraction of a multi-fault in gearboxes is difficult to achieve. Due to improper selection of methods, leakage diagnosis or misdiagnosis will usually occur. Ensemble Empirical Mode Decomposition (EEMD) often causes energy leakage due to improper selection of white noise during signal decomposition. Considering that only a single fault cycle can be extracted when MOMED (Multipoint Optimal Minimum Entropy Deconvolution) is used, it is necessary to perform the sub-band processing of the compound fault signal. This paper presents an adaptive gearbox multi-fault-feature extraction method based on Improved MOMED (IMOMED). Firstly, EEMD decomposes the signal adaptively and selects the intrinsic mode functions with strong correlation with the original signal to perform FFT (Fast Fourier transform); considering the mode-mixing phenomenon of EEMD, reconstruct the intrinsic mode functions with the same timescale, and obtain several intrinsic mode functions of the same scale to improve the entropy of fault features. There is a lot of white noise in the original signal, and EEMD can improve the signal-to-noise ratio of the original signal. Finally, through the setting of different noise-reduction intervals to extract fault features through MOMED. The proposed method is compared with EEMD and VMD (Variational Mode Decomposition) to verify its feasibility.

Planetary Gear Fault Diagnosis via Feature Image Extraction Based on Multi Central Frequencies and Vibration Signal Frequency Spectrum

Poor working environment leads to frequent failures of planetary gear trains. However, complex structure and variable transmission make the vibration signal strongly non-linear and non-stationary, which brings big problems to fault diagnosis. A method of planetary gear fault diagnosis via feature image extraction based on multi central frequencies and vibration signal frequency spectrum is proposed. The original vibration signal is decomposed by variational mode decomposition (VMD), and four components with narrow bands and independent central frequencies are decomposed. In order to retain the feature spectrum of the original vibration signal as far as possible, the corresponding feature bands are intercepted from the frequency spectrum of original vibration signal based on the central frequency of each component. Then, the feature images of fault signals are constructed as the inputs of the convolution neural network (CNN), and the parameters of the neural network are optimized by sample training. Finally, the optimized CNN is used to identify fault signals. The overall fault recognition rate is up to 98.75%. Compared with the feature bands extracted directly from the component spectrums, the extraction method of the feature bands proposed in this paper needs fewer iterations under the same network structure. The method of planetary gear fault diagnosis proposed in this paper is effective.

A Distributed Learning Method for ℓ 1 -Regularized Kernel Machine over Wireless Sensor Networks

In wireless sensor networks, centralized learning methods have very high communication costs and energy consumption. These are caused by the need to transmit scattered training examples from various sensor nodes to the central fusion center where a classifier or a regression machine is trained. To reduce the communication cost, a distributed learning method for a kernel machine that incorporates ℓ1 norm regularization (ℓ1-regularized) is investigated, and a novel distributed learning algorithm for the ℓ1-regularized kernel minimum mean squared error (KMSE) machine is proposed. The proposed algorithm relies on in-network processing and a collaboration that transmits the sparse model only between single-hop neighboring nodes. This paper evaluates the proposed algorithm with respect to the prediction accuracy, the sparse rate of model, the communication cost and the number of iterations on synthetic and real datasets. The simulation results show that the proposed algorithm can obtain approximately the same prediction accuracy as that obtained by the batch learning method. Moreover, it is significantly superior in terms of the sparse rate of model and communication cost, and it can converge with fewer iterations. Finally, an experiment conducted on a wireless sensor network (WSN) test platform further shows the advantages of the proposed algorithm with respect to communication cost.

Multi-Sensor Data Fusion Identification for Shearer Cutting Conditions Based on Parallel Quasi-Newton Neural Networks and the Dempster-Shafer Theory

In order to efficiently and accurately identify the cutting condition of a shearer, this paper proposed an intelligent multi-sensor data fusion identification method using the parallel quasi-Newton neural network (PQN-NN) and the Dempster-Shafer (DS) theory. The vibration acceleration signals and current signal of six cutting conditions were collected from a self-designed experimental system and some special state features were extracted from the intrinsic mode functions (IMFs) based on the ensemble empirical mode decomposition (EEMD). In the experiment, three classifiers were trained and tested by the selected features of the measured data, and the DS theory was used to combine the identification results of three single classifiers. Furthermore, some comparisons with other methods were carried out. The experimental results indicate that the proposed method performs with higher detection accuracy and credibility than the competing algorithms. Finally, an industrial application example in the fully mechanized coal mining face was demonstrated to specify the effect of the proposed system.