Abstract

In recent decades, hybridization of superior attributes of few algorithms was proposed to aid in covering more areas of complex application as well as improves performance. Condition monitoring is a major component in predictive maintenance which monitors the condition and identifies significant changes in the machinery parameter to perform early detection and prevent equipment defects that could cause unplanned downtime or incur unnecessary expenditures. An effective condition monitoring model is helpful to reduce the frequency of unexpected breakdown incidents and thus, facilitates in maintenance. ANN has shown effective in various condition monitoring and fault detection applications. ANN is popular due to its capability of identifying the complex nonlinear relationships among features in a large dataset and hence, it can perform with an accurate prediction. However, a drawback is that the performance of ANN is sensitive to the parameters (i.e., number of hidden neurons and the initial values of connection weights) in its architecture where the settings of these parameters are subject to tuning on a trial-and-error basis. Hence, a wide range of studies have been focused on determining the optimal weight values of ANN models and the number of hidden neurons. In this research work, the motivation is to develop an autonomous learning model based on the hybridization of an adaptive ANN and a metaheuristic algorithm for optimizing ANN parameters so that the network could perform learning and adaptation in a more flexible way and handle condition classification tasks more accurately in industries, such as in power systems. This paper presents an intelligent system integrating a Radial Basis Function Network with Dynamic Decay Adjustment (RBFN-DDA) with a Harmony Search (HS) to perform condition monitoring in industrial processes. RBFN-DDA performs incremental learning wherein its structure expands by adding new hidden units to include new information. As such, its training can reach stability in a shorter time compared to the gradient-descent based methods. To achieve optimal RBFN-DDA performance, HS is proposed to optimize the center and the width of each hidden unit in a trained RBFN. By integrating with the HS algorithm, the proposed metaheuristic neural network (RBFN-DDA-HS) can optimize the RBFN-DDA parameters and improve classification performances from the original RBFN-DDA by 2.2% up to 22.5% in two benchmarks datasets, which are numerical records from a bearing and steel plate system and a condition-monitoring system in a power plant (i.e., the circulating water (CW) system). The results also show that the proposed RBFN-DDA-HS is compatible, if not better than, the classification performances of other state-of-the-art machine learning methods.

Highlights

  • Maintenance involves carrying out all technical and associated administrative activities to keep all components in an operational system to perform their function properly [1]

  • Extensive research have been focused on a data classification approach to fault detection in the manufacturing industry such as tool wear monitoring and machining parameter prediction that are described in Session 2.2

  • Condition monitoring and fault detection techniques are applied in power generation industry with an intention to avoid sudden breakdowns which may result in costly repair and machine unavailability

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Summary

Introduction

Maintenance involves carrying out all technical and associated administrative activities to keep all components in an operational system to perform their function properly [1]. Literature shows that ANNs with learning capabilities are useful models for tackling condition based maintenance problems [9]. They learn from data samples without a requirement for building an exact mathematical model. An effective evolutionary ANN-based condition monitoring model is helpful to reduce the frequency of unexpected breakdown incidents and facilitate in maintenance. This motivates a research on developing an autonomous learning model based on the hybridization of an adaptive ANN and a metaheuristic algorithm for handling condition classification tasks in industries, such as in power systems. The research work is aimed at developing an evolutionary ANN for monitoring operating states of a system more accurately in a power plant

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