Rolling Bearing Fault Diagnosis Based on an Improved HTT Transform

Lightweight Ghost Enhanced Feature Attention Network: An Efficient Intelligent Fault Diagnosis Method under Various Working Conditions

Recent advancements in applications of deep neural network for bearing fault diagnosis under variable operating conditions have shown promising outcomes. However, these approaches are limited in practical applications due to the complexity of neural networks, which require substantial computational resources, thereby hindering the advancement of automated diagnostic tools. To overcome these limitations, this study introduces a new fault diagnosis framework that incorporates a tri-channel preprocessing module for multidimensional feature extraction, coupled with an innovative diagnostic architecture known as the Lightweight Ghost Enhanced Feature Attention Network (GEFA-Net). This system is adept at identifying rolling bearing faults across diverse operational conditions. The FFE module utilizes advanced techniques such as Fast Fourier Transform (FFT), Frequency Weighted Energy Operator (FWEO), and Signal Envelope Analysis to refine signal processing in complex environments. Concurrently, GEFA-Net employs the Ghost Module and the Efficient Pyramid Squared Attention (EPSA) mechanism, which enhances feature representation and generates additional feature maps through linear operations, thereby reducing computational demands. This methodology not only significantly lowers the parameter count of the model, promoting a more streamlined architectural framework, but also improves diagnostic speed. Additionally, the model exhibits enhanced diagnostic accuracy in challenging conditions through the effective synthesis of local and global data contexts. Experimental validation using datasets from the University of Ottawa and our dataset confirms that the framework not only achieves superior diagnostic accuracy but also reduces computational complexity and accelerates detection processes. These findings highlight the robustness of the framework for bearing fault diagnosis under varying operational conditions, showcasing its broad applicational potential in industrial settings. The parameter count was decreased by 63.74% compared to MobileVit, and the recorded diagnostic accuracies were 98.53% and 99.98% for the respective datasets.

Advancing aircraft engine RUL predictions: an interpretable integrated approach of feature engineering and aggregated feature importance

In this study, we present a comprehensive approach for predicting the remaining useful life (RUL) of aircraft engines, incorporating advanced feature engineering, dimensionality reduction, feature selection techniques, and machine learning models. The process begins with a rolling time series window, followed by the extraction of a multitude of statistical features, and the application of principal component analysis for dimensionality reduction. We utilize a variety of feature selection methods, such as Genetic Algorithm, Recursive Feature Elimination, Least Absolute Shrinkage and Selection Operator Regression, and Feature Importances from a Random Forest model. As a significant contribution, we introduce the novel aggregated feature importances with cross-validation (AFICv) technique, which ranks features based on their mean importance. We establish a selection criterion that retains features with a cumulative mean sum equal to 70%, thereby reducing the complexity of machine learning models and enhancing their generalizability. Four machine learning regression models-Natural and Extreme Gradient Boosting, Random Forest, and Multi-Layer Perceptron-were employed to evaluate the effectiveness of the selected features. The performance of our proposed method is assessed by the evaluation metrics Root Mean Square Error (RMSE) and R2 Score, and also considered within-interval percentages and relative accuracy metrics. Importantly, a novel PCA interpretability was introduced to provide real-world context and enhance the utility of our findings for domain experts. Our results indicate that the proposed AFICv technique efficiently achieves competitive performance across the Commercial Modular Aero-Propulsion System Simulation (C-MAPSS) sub-datasets using a significantly smaller subset of features, thus contributing to a more effective and interpretable RUL prediction methodology for aircraft engines.

Bearing Fault Diagnosis Using Multidomain Fusion-Based Vibration Imaging and Multitask Learning

Statistical features extraction from bearing fault signals requires a substantial level of knowledge and domain expertise. Furthermore, existing feature extraction techniques are mostly confined to selective feature extraction methods namely, time-domain, frequency-domain, or time-frequency domain statistical parameters. Vibration signals of bearing fault are highly non-linear and non-stationary making it cumbersome to extract relevant information for existing methodologies. This process even became more complicated when the bearing operates at variable speeds and load conditions. To address these challenges, this study develops an autonomous diagnostic system that combines signal-to-image transformation techniques for multi-domain information with convolutional neural network (CNN)-aided multitask learning (MTL). To address variable operating conditions, a composite color image is created by fusing information from multi-domains, such as the raw time-domain signal, the spectrum of the time-domain signal, and the envelope spectrum of the time-frequency analysis. This 2-D composite image, named multi-domain fusion-based vibration imaging (MDFVI), is highly effective in generating a unique pattern even with variable speeds and loads. Following that, these MDFVI images are fed to the proposed MTL-based CNN architecture to identify faults in variable speed and health conditions concurrently. The proposed method is tested on two benchmark datasets from the bearing experiment. The experimental results suggested that the proposed method outperformed state-of-the-arts in both datasets.

A Fault Diagnosis Approach for Rolling Bearing Integrated SGMD, IMSDE and Multiclass Relevance Vector Machine

The vibration signal induced by bearing local fault has strong nonstationary and nonlinear property, which indicates that the conventional methods are difficult to recognize bearing fault patterns effectively. Hence, to obtain an efficient diagnosis result, the paper proposes an intelligent fault diagnosis approach for rolling bearing integrated symplectic geometry mode decomposition (SGMD), improved multiscale symbolic dynamic entropy (IMSDE) and multiclass relevance vector machine (MRVM). Firstly, SGMD is employed to decompose the original bearing vibration signal into several symplectic geometry components (SGC), which is aimed at reconstructing the original bearing vibration signal and achieving the purpose of noise reduction. Secondly, the bat algorithm (BA)-based optimized IMSDE is presented to evaluate the complexity of reconstruction signal and extract bearing fault features, which can solve the problems of missing of partial fault information existing in the original multiscale symbolic dynamic entropy (MSDE). Finally, IMSDE-based bearing fault features are fed to MRVM for achieving the identification of bearing fault categories. The validity of the proposed method is verified by the experimental and contrastive analysis. The results show that our approach can precisely identify different fault patterns of rolling bearings. Moreover, our approach can achieve higher recognition accuracy than several existing methods involved in this paper. This study provides a new research idea for improvement of bearing fault identification.

Fault Diagnosis in the Slip-Frequency Plane of Induction Machines Working in Time-Varying Conditions

Motor current signature analysis (MCSA) is a fault diagnosis method for induction machines (IMs) that has attracted wide industrial interest in recent years. It is based on the detection of the characteristic fault signatures that arise in the current spectrum of a faulty induction machine. Unfortunately, the MCSA method in its basic formulation can only be applied in steady state functioning. Nevertheless, every day increases the importance of inductions machines in applications such as wind generation, electric vehicles, or automated processes in which the machine works most of time under transient conditions. For these cases, new diagnostic methodologies have been proposed, based on the use of advanced time-frequency transforms—as, for example, the continuous wavelet transform, the Wigner Ville distribution, or the analytic function based on the Hilbert transform—which enables to track the fault components evolution along time. All these transforms have high computational costs and, furthermore, generate as results complex spectrograms, which require to be interpreted for qualified technical staff. This paper introduces a new methodology for the diagnosis of faults of IM working in transient conditions, which, unlike the methods developed up to today, analyzes the current signal in the slip-instantaneous frequency plane (s-IF), instead of the time-frequency (t-f) plane. It is shown that, in the s-IF plane, the fault components follow patterns that that are simple and unique for each type of fault, and thus does not depend on the way in which load and speed vary during the transient functioning; this characteristic makes the diagnostic task easier and more reliable. This work introduces a general scheme for the IMs diagnostic under transient conditions, through the analysis of the stator current in the s-IF plane. Another contribution of this paper is the introduction of the specific s-IF patterns associated with three different types of faults (rotor asymmetry fault, mixed eccentricity fault, and single-point bearing defects) that are theoretically justified and experimentally tested. As the calculation of the IF of the fault component is a key issue of the proposed diagnostic method, this paper also includes a comparative analysis of three different mathematical tools for calculating the IF, which are compared not only theoretically but also experimentally, comparing their performance when are applied to the tested diagnostic signals.

Anti-Interference Deep Visual Identification Method for Fault Localization of Transformer Using a Winding Model

The idea of Ubiquitous Power Internet of Things (UPIoTs) accelerates the development of intelligent monitoring and diagnostic technologies. In this paper, a diagnostic method suitable for power equipment in an interference environment was proposed based on the deep Convolutional Neural Network (CNN): MobileNet-V2 and Digital Image Processing (DIP) methods to conduct fault identification process: including fault type classification and fault localization. A data visualization theory was put forward in this paper, which was applied in frequency response (FR) curves of transformer to obtain dataset. After the image augmentation process, the dataset was input into the deep CNN: MobileNet-V2 for training procedures. Then a spatial-probabilistic mapping relationship was established based on traditional Frequency Response Analysis (FRA) fault diagnostic method. Each image in the dataset was compared with the fingerprint values to get traditional diagnosing results. Next, the anti-interference abilities of the proposed CNN-DIP method were compared with that of the traditional one while the magnitude of the interference gradually increased. Finally, the fault tolerance of the proposed method was verified by further analyzing the deviations between the wrong diagnosing results with the corresponding actual labels. Experimental results showed that the proposed deep visual identification (CNN-DIP) method has a higher diagnosing accuracy, a stronger anti-interference ability and a better fault tolerance.

Cost-Effective Reduced Envelope of the Stator Current via Synchronous Sampling for the Diagnosis of Rotor Asymmetries in Induction Machines Working at Very Low Slip

Fault diagnosis of rotor asymmetries of induction machines (IMs) using the stator current relies on the detection of the characteristic signatures of the fault harmonics in the current spectrum. In some scenarios, such as large induction machines running at a very low slip, or unloaded machines tested offline, this technique may fail. In these scenarios, the fault harmonics are very close to the frequency of the fundamental component, and have a low amplitude, so that they may remain undetected, buried under the fundamental’s leakage, until the damage is severe. To avoid false positives, a proven approach is to search for the fault harmonics in the current envelope, instead of the current itself, because in this case the spectrum is free from the leakage of the fundamental. Besides, the fault harmonics appear at a very low frequency. Nevertheless, building the current spectrum is costly in terms of computing complexity, as in the case of the Hilbert transform, or hardware resources, as in the need for simultaneously sampling three stator currents in the case of the extended current Park’s vector approach (EPVA). In this work, a novel method is proposed to avoid this problem. It is based on sampling a phase current just twice per current cycle, with a fixed delay with respect to its zero crossings. It is shown that the spectrum of this reduced set of current samples contains the same fault harmonics as the spectrum of the full-length current envelope, despite using a minimal amount of computing resources. The proposed approach is cost-effective, because the computational requirements for building the current envelope are reduced to less than 1% of those required by other conventional methods, in terms of storage and computing time. In this way, it can be implemented with low-cost embedded devices for on-line fault diagnosis. The proposed approach is introduced theoretically and validated experimentally, using a commercial induction motor with a broken bar under different load and supply conditions. Besides, the proposed approach has been implemented on a low-cost embedded device, which can be accessed on-line for remote fault diagnosis.

Gearbox Fault Diagnosis Based on Hierarchical Instantaneous Energy Density Dispersion Entropy and Dynamic Time Warping

The accurate fault diagnosis of gearboxes is of great significance for ensuring safe and efficient operation of rotating machinery. This paper develops a novel fault diagnosis method based on hierarchical instantaneous energy density dispersion entropy (HIEDDE) and dynamic time warping (DTW). Specifically, the instantaneous energy density (IED) analysis based on singular spectrum decomposition (SSD) and Hilbert transform (HT) is first applied to the vibration signal of gearbox to acquire the IED signal, which is designed to reinforce the fault feature of the signal. Then, the hierarchical dispersion entropy (HDE) algorithm developed in this paper is used to quantify the complexity of the IED signal to obtain the HIEDDE as fault features. Finally, the DTW algorithm is employed to recognize the fault types automatically. The validity of the two parts that make up the HIEDDE algorithm, i.e., the IED analysis for fault features enhancement and the HDE algorithm for quantifying the information of signals, is numerically verified. The proposed method recognizes the fault patterns of the experimental data of gearbox accurately and exhibits advantages over the existing methods such as multi-scale dispersion entropy (MDE) and refined composite MDE (RCMDE).

Smart Fault-Detection Machine for Ball-Bearing System with Chaotic Mapping Strategy

In this paper, a set of smart fault-detection approach with chaotic mapping strategy is developed for an industrial ball-bearing system. There are four main statuses in this ball-bearing system: normal, inner race fault, outer race fault, and ball fault. However, it is hard to simply classify each of them through their vibration signals in time-series. By developing a nonlinear error dynamic system as well as a chaotic mapping strategy, the signals in the time series can be converted into the chaotic domain, which are revealed in 3D phase portraits. Further, through collocation of clustering methods, such as Euclidean distance (ED) and the kernel method of K-means (KM), the proposed 3D phase portraits of each different state can be efficiently identified through checking the autonomously adjusted ranges of feature values. The experiment results show that the proposed smart detection approach is effective and feasible, and the accuracy of detection in the testing stage is close to 100%.

Extreme Interval Entropy Based on Symbolic Analysis and a Self-Adaptive Method

Self-adaptive methods are recognized as important tools in signal process and analysis. A signal can be decomposed into a serious of new components with these mentioned methods, thus the amount of information is also increased. In order to use these components effectively, a feature set is used to describe them. With the development of pattern recognition, the analysis of self-adaptive components is becoming more intelligent and depend on feature sets. Thus, a new feature is proposed to express the signal based on the hidden property between extreme values. In this investigation, the components are first simplified through a symbolization method. The entropy analysis is incorporated into the establishment of the characteristics to describe those self-adaptive decomposition components according to the relationship between extreme values. Subsequently, Extreme Interval Entropy is proposed and used to realize the pattern recognition, with two typical self-adaptive methods, based on both Empirical Mode Decomposition (EMD) and Empirical Wavelet Transform (EWT). Later, extreme interval entropy is applied in two fault diagnosis experiments. One experiment is the fault diagnosis for rolling bearings with both different faults and damage degrees, the other experiment is about rolling bearing in a printing press. The effectiveness of the proposed method is evaluated in both experiments with K-means cluster. The accuracy rate of the fault diagnosis in rolling bearing is in the range of 75% through 100% using EMD, 95% through 100% using EWT. In the printing press experiment, the proposed method can reach 100% using EWT to distinguish the normal bearing (but cannot distinguish normal samples at different speeds), with fault bearing in 4 r/s and in 8 r/s. The fault samples are identified only according to a single proposed feature with EMD and EWT. Therefore, the extreme interval entropy is proved to be a reliable and effective tool for fault diagnosis and other similar applications.

Optimized Adaptive Local Iterative Filtering Algorithm Based on Permutation Entropy for Rolling Bearing Fault Diagnosis

The characteristics of the early fault signal of the rolling bearing are weak and this leads to difficulties in feature extraction. In order to diagnose and identify the fault feature from the bearing vibration signal, an adaptive local iterative filter decomposition method based on permutation entropy is proposed in this paper. As a new time-frequency analysis method, the adaptive local iterative filtering overcomes two main problems of mode decomposition, comparing traditional methods: modal aliasing and the number of components is uncertain. However, there are still some problems in adaptive local iterative filtering, mainly the selection of threshold parameters and the number of components. In this paper, an improved adaptive local iterative filtering algorithm based on particle swarm optimization and permutation entropy is proposed. Firstly, particle swarm optimization is applied to select threshold parameters and the number of components in ALIF. Then, permutation entropy is used to evaluate the mode components we desire. In order to verify the effectiveness of the proposed method, the numerical simulation and experimental data of bearing failure are analyzed.

Theoretical Analysis of Empirical Mode Decomposition

This work suggests a theoretical principle about the oscillation signal decomposition, which is based on the requirement of a pure oscillation component, in which the mean zero is extracted from the signal. Using this principle, the validity and robustness of the empirical mode decomposition (EMD) method are first proved mathematically. This work also presents a modified version of EMD by the interpolation solution, which is able to improve the frequency decomposition of the signal. The result shows that it can provide a primary theoretical basis for the development of EMD. The simulation signal verifies the effectiveness of the EMD algorithm. At the same time, compared with the existing denoising algorithm, it has achieved good results in the denoising of rolling bearing fault signals. It contributes to the development and improvement of adaptive signal processing theory in the field of fault diagnosis. It provides practical value research results for the rapid development of adaptive technology in the field of fault diagnosis.

Fault Diagnosis of Rolling Bearings Based on Improved Fast Spectral Correlation and Optimized Random Forest

Fault diagnosis of rolling bearings is important for ensuring the safe operation of industrial machinery. How to effectively extract the fault features and select a classifier with high precision is the key to realizing the fault recognition of bearings. Accordingly, a new fault diagnosis method of rolling bearings based on improved fast spectral correlation and optimized random forest (i.e., particle swarm optimization-random forest (PSO-RF)) is proposed in this paper. The main contributions of this study are made from two aspects. One is that an improved fast spectral correlation approach was developed to extract the fault features of bearings and form the feature vector more effectively. The other is that an optimized random forest classifier was developed to achieve highly accurate identification by exploiting particle swarm optimization to select the best parameters of random forest (RF). In the presented method, improved fast spectral correlation was first utilized to analyze the raw vibration signal caused by a faulty bearing to obtain the enhanced envelope spectrum. Then, the amplitudes of the four characteristic cyclic frequencies (i.e., the rotating frequency, the characteristic frequency of outer-race fault, the characteristic frequency of inner-race fault, and the characteristic frequency of rolling element fault) exhibited in the enhanced envelope spectrum were selected to form the feature vector. Finally, the PSO-RF method was introduced for identifying and classifying bearing faults. The experimental investigations demonstrate the proposed method can accurately identify bearing faults and outperform other state-of-art techniques considered.

Intelligent Ball Bearing Fault Diagnosis Using Fractional Lorenz Chaos Extension Detection

In this study we used a non-autonomous Chua's circuit, and the fractional Lorenz chaos system. This was combined with the Extension theory detection method to analyze the voltage signals. The bearing vibration signals, measured using an acceleration sensor, were introduced into the master and slave systems through a Chua's circuit. In a chaotic system, minor differences can cause significant changes that generate dynamic errors. The matter-element model extension can be used to determine the bearing condition. Extension theory can be used to establish classical and sectional domains using the dynamic errors of the fault conditions. The results obtained were compared with those from discrete Fourier transform analysis, wavelet analysis and an integer order chaos system. The diagnostic rate of the fractional-order master and slave chaotic system could reach 100% if the fractional-order parameter adjustment was used. This study presents a very efficient and inexpensive method for monitoring the state of ball bearings.

Fault Severity Monitoring of Rolling Bearings Based on Texture Feature Extraction of Sparse Time–Frequency Images

Rolling bearings are important components of rotating machines. For their preventive maintenance, it is not enough to know whether there is any fault or the fault type. For an effective maintenance, a fault severity monitoring needs to be conducted. Currently, the bearing fault diagnosis method based on time–frequency image (TFI) recognition is attracting increasing attention. This paper contributes to the ongoing investigation by proposing a new approach for the fault severity monitoring of rolling bearings based on the texture feature extraction of sparse TFIs. The first and main step is to obtain accurate TFIs from the vibration signals of rolling bearings. Traditional time–frequency analysis methods have disadvantages such as low resolution and cross-term interference. Therefore, the TFIs obtained cannot satisfactorily express the time–frequency characteristics of bearing vibration signals. To solve this problem, a sparse time–frequency analysis method based on the first-order primal-dual algorithm (STFA-PD) was developed in this paper. Unlike traditional time–frequency analysis methods, the time–frequency analysis model of the STFA-PD method is based on the theory of sparse representation, and is solved using the first-order primal-dual algorithm. For employing the sparse constraint in the frequency domain, the STFA-PD obtains a higher time–frequency resolution and is free from cross-term interference, as the model is based on a linear time–frequency analysis method. The gray level co-occurrence matrix is then employed to extract texture features from the sparse TFIs as input features for classifiers. Vibration signals of rolling bearings with different fault severity degrees are used to validate the proposed approach. The experimental results show that the developed STFA-PD outperforms traditional time–frequency analysis methods in terms of the accuracy and effectiveness for the fault severity monitoring of rolling bearings.

Partial Inductance Model of Induction Machines for Fault Diagnosis

The development of advanced fault diagnostic systems for induction machines through the stator current requires accurate and fast models that can simulate the machine under faulty conditions, both in steady-state and in transient regime. These models are far more complex than the models used for healthy machines, because one of the effect of the faults is to change the winding configurations (broken bar faults, rotor asymmetries, and inter-turn short circuits) or the magnetic circuit (eccentricity and bearing faults). This produces a change of the self and mutual phase inductances, which induces in the stator currents the characteristic fault harmonics used to detect and to quantify the fault. The development of a machine model that can reflect these changes is a challenging task, which is addressed in this work with a novel approach, based on the concept of partial inductances. Instead of developing the machine model based on the phases’ coils, it is developed using the partial inductance of a single conductor, obtained through the magnetic vector potential, and combining the partial inductances of all the conductors with a fast Fourier transform for obtaining the phases’ inductances. The proposed method is validated using a commercial induction motor with forced broken bars.

Rolling Bearing Fault Diagnosis Based on Optimal Notch Filter and Enhanced Singular Value Decomposition

The impulsive fault feature signal of rolling bearings at the early failure stage is easily contaminated by the fundamental frequency (i.e., the rotation frequency of the shaft) signal and background noise. To address this problem, this paper puts forward a rolling bearing weak fault diagnosis method with the combination of optimal notch filter and enhanced singular value decomposition. Firstly, in order to eliminate the interference of the fundamental frequency signal, the original signal was processed by the notch filter with the fundamental frequency as the center frequency and with a varying bandwidth to get a series of corresponding notch filter signals. Secondly, the Teager energy entropy index was adopted to adaptively determine the optimal bandwidth to complete the optimal notch filter analysis on the raw vibration signal and obtain the corresponding optimal notch filter signal. Thirdly, an enhanced singular value decomposition de-nosing method was employed to de-noise the optimal notch filter signal. Finally, the envelope spectrum analysis was conducted on the de-noised signal to extract the fault characteristic frequencies. The effectiveness of the presented method was demonstrated via simulation and experiment verifications. In addition, the minimum entropy deconvolution, Kurtogram and Infogram methods were employed for comparisons to show the advantages of the presented method.

Improved Dynamic Mode Decomposition and Its Application to Fault Diagnosis of Rolling Bearing

To solve the intractable problems of optimal rank truncation threshold and dominant modes selection strategy of the standard dynamic mode decomposition (DMD), an improved DMD algorithm is introduced in this paper. Distinct from the conventional methods, a convex optimization framework is introduced by applying a parameterized non-convex penalty function to obtain the optimal rank truncation number. This method is inspirited by the performance that it is more perfectible than other rank truncation methods in inhibiting noise disturbance. A hierarchical and multiresolution application similar to the process of wavelet packet decomposition in modes selection is presented so as to improve the algorithm's performance. With the modes selection strategy, the frequency spectrum of the reconstruction signal is more readable and interference-free. The improved DMD algorithm successfully extracts the fault characteristics of rolling bearing fault signals when it is utilized for mechanical signal feature extraction. Results demonstrated that the proposed method has good application prospects in denoising and fault feature extraction for mechanical signals.