Automatic Fault Classification Research Articles

Novel mining conveyor monitoring system based on quasi-distributed optical fiber accelerometer array and self-supervised learning

Belt conveyors in mining are crucial, with downtime leading to significant losses and safety hazards. Unplanned shutdowns often result from idler failures. To address this, an online monitoring system for continuous idler health assessment is proposed. Considering the large number and dense spatial distribution of idlers over long distances, this work presents a system that utilizes a quasi-distributed optical fiber accelerometer array. This array incorporates phase-sensitive optical time domain reflectometry (Phase-OTDR) interrogation technology and ultra-weak fiber Bragg gratings (UWFBGs) to effectively capture idler vibrations. The designed array achieves high-sensitivity vibration sensing with a sensitivity of 2.4 rad/g and a resolution of 1.7 mg/Hz. After collecting the vibrations of idlers by the designed accelerometer array, an automatic fault classification algorithm based on self-supervised learning (SSL) is introduced, which requires only a small number of labeled samples. By leveraging large amount of unlabeled data in the pretext task, the algorithm efficiently extracts latent features from the quasi-distributed accelerometer array. A diagnosis accuracy of 95.37 % can be achieved on a seven-class classification task with only 3.6 % labeled data (16 samples/class). This system offers a promising solution for idler monitoring, combining high sensitivity, distributed measurement capabilities, enhanced security, and superior fault detection accuracy.

An Efficient Approach for Automatic Fault Classification Based on Data Balance and One-Dimensional Deep Learning

Predictive maintenance (PdM) is implemented to efficiently manage maintenance schedules of machinery and equipment in manufacturing by predicting potential faults with advanced technologies such as sensors, data analysis, and machine learning algorithms. This paper introduces a study of different methodologies for automatically classifying the failures in PdM data. We first present the performance evaluation of fault classification performed by shallow machine learning (SML) methods such as Decision Trees, Support Vector Machines, k-Nearest Neighbors, and one-dimensional deep learning (DL) techniques like 1D-LeNet, 1D-AlexNet, and 1D-VGG16. Then, we apply normalization, which is a scaling technique in which features are shifted and rescaled in the dataset. We reapply classification algorithms to the normalized dataset and present the performance tables in comparison with the first results we obtained. Moreover, in contrast to existing studies in the literature, we generate balanced dataset groups by randomly selecting normal data and all faulty data for all fault types from the original dataset. The dataset groups are generated with 100 different repetitions, recording performance scores for each one and presenting the maximum scores. All methods utilized in the study are similarly employed on these groups. From these scores, the use of 1D-LeNet deep learning classifiers and feature normalization resulted in achieving the highest overall accuracy and F1-score performance of 98.50% and 98.32%, respectively. As a result, the goal of this study was to develop an efficient approach for automatic fault classification, leveraging data balance, and additionally, to provide an analysis of one-dimensional deep learning and shallow machine learning-based classification methods. In light of the experimentation and comparative analysis, this study successfully achieves its stated goal by demonstrating that one-dimensional deep learning and data balance collectively emerge as the optimal approach, offering good prediction accuracy.

Application of EMD ANN and DNN for Self-Aligning Bearing Fault Diagnosis

Self-aligning roller bearings are an integral part of the industrial machinery. The proper analysis and prediction of the various faults that may happen to the bearing beforehand contributes to an increase in the working life of the bearing. This study aims at developing a novel method for the analysis of the various faults in self-aligning bearings as well as the automatic classification of faults using artificial neural network (ANN) and deep neural network (DNN). The vibration data is collected for six different faults as well as for the healthy bearing. Empirical mode decomposition (EMD) followed by Hilbert Huang transform is used to extract instantaneous frequency peaks which are used for fault analysis. Time domain and time-frequency domain features are then extracted which are used to implement the neural networks through the pattern recognition tool in MATLAB. A comparative study of the outputs from the two neural networks is also performed. From the confusion matrix, the efficiency of the ANN has been found to be 95.7% and using DNN has been found to be 100%.

Automatic Fault Classification for Journal Bearings Using ANN and DNN

Journal bearings are the most common type of bearings in which a shaft freely rotates in a metallic sleeve. They find a lot of applications in industry, especially where extremely high loads are involved. Proper analysis of the various bearing faults and predicting the modes of failure beforehand are essential to increase the working life of the bearing. In the current study, the vibration data of a journal bearing in the healthy condition and in five different fault conditions are collected. A feature extraction method is employed to classify the different fault conditions. Automatic fault classification is performed using artificial neural networks (ANN). As the probability of a correct prediction goes down for a higher number of faults in ANN, the method is made more robust by incorporating deep neural networks (DNN) with the help of autoencoders. Training was done using the scaled conjugate gradient algorithm and the performance was calculated by the cross entropy method. Due to the increased number of hidden layers in DNN, it is possible to achieve a high efficiency of 100% with the feature extraction method.

Modeling and Simulation of Time Domain Reflectometry Signals on a Real Network for Use in Fault Classification and Location

Today, the classification and location of faults in electrical networks remains a topic of great interest. Faults are a major issue, mainly due to the time spent to detect, locate, and repair the cause of the fault. To reduce time and associated costs, automatic fault classification and location is gaining great interest. State-of-the-art techniques to classify and locate faults are mainly based on line-impedance measurements or the detection of the traveling wave produced by the event caused by the fault itself. In contrast, this paper describes the methodology for creating a database and a model for a complex distribution network. Both objectives are covered under the paradigm of the time-domain pulse reflectometry (TDR) principle. By using this technique, large distances can be monitored on a line with a single device. Thus, in this way a database is shared and created from the results of simulations of a real and complex distribution network modeled in the PSCAD™ software, which have been validated with measurements from an experimental test setup. Experimental validations have shown that the combination of the TDR technique with the modeling of a real network (including the real injector and the network coupling filter from the prototype) provides high-quality signals that are very similar and reliable to the real ones. In this sense, it is intended firstly that this model and its corresponding data will serve as a basis for further processing by any of the existing state-of-the-art techniques. And secondly, to become a valid alternative to the already well-known Test Feeders but adapted to work groups not used to the electrical world but to the environment of pure data processing.

Intrinsic component filtering for fault diagnosis of rotating machinery

Fault diagnosis of rotating machinery has always drawn wide attention. In this paper, Intrinsic Component Filtering (ICF), which achieves population sparsity and lifetime consistency using two constraints: l1/2 norm of column features and l3/2 -norm of row features, is proposed for the machinery fault diagnosis. ICF can be used as a feature learning algorithm, and the learned features can be fed into the classification to achieve the automatic fault classification. ICF can also be used as a filter training method to extract and separate weak fault components from the noise signals without any prior experience. Simulated and experimental signals of bearing fault are used to validate the performance of ICF. The results confirm that ICF performs superior in three fault diagnosis fields including intelligent fault diagnosis, weak signature detection and compound fault separation.

Fuzzy Inference System to Automatic Fault Classification in Power Plants

The increase in size of the current electric power systems has led to the development of monitoring techniques that includes online and offline analysis. One of the most common offline techniques is the disturbance records systems, based on oscillographic records, generated by Digital Fault Recorders and allow the analysis of the electrical quantities and logical signal (from protection devices). Generally, in power plants, all the data are centralized in the utility data center and this results in an excess of data that difficults the task of analysis by the specialist engineers. This paper shows a methodology for automatic analysis of disturbances in power plants based on fuzzy reasoning. The objective of the system is to help the engineer responsible for the analysis of the records by means of a pre-classification of data and also, diagnose the relevant occurrences.

Application of Time-Frequency Analysis & Blind Source Separation to Diagnosis of Faults with Generator Rotor System

One method for diagnosis of faults with generator rotor is contrived by combining local wave method and blind source separation. Time-frequency image varies with local wave of different fault signals, and this feature is applied to identify different faults. In order to realize automatic classification of faults, blind source separation is employed for separation of independent components in time-frequency image of local wave of different fault signals, so as to derive projection coefficients for a set of source images. On the basis of this, automatic classification of faults is realized with probability nerve network. Taking fault signal of rotor as an example, this method is investigated, and the validity is proved by experimental results.

Autonomous Neural Models for the Classification of Events in Power Distribution Networks

This paper presents a method for automatic classification of faults and transients in power distribution networks, based on voltage oscillographies of the distribution networks feeders. For signal preprocessing, the discrete wavelet transform was used with the performances of several families of wavelet functions being compared. In the classification stage, three neural models were assessed: multi-layer perceptrons, radial basis function networks, and support vector machines. The models were trained autonomously, i.e., using automatic model selection and complexity control. Promising results were obtained using a set of simulations generated using the Alternative Transients Program (ATP). Initial results obtained for real data acquired from a set of oscillograph loggers installed in a distribution network are also presented.

Application of S transform and morphological pattern spectrum for gear fault diagnosis

Time–frequency representations (TFR) have been intensively employed for analysing vibration signals in gear fault diagnosis. However, in many applications, TFR are simply utilized as a visual aid to detect gear defects. An attractive issue is to utilize the TFR for automatic classification of faults. A key step for this study is to extract discriminative features from TFR as input feature vector for classifiers. This article contributes to this ongoing investigation by applying morphological pattern spectrum (MPS) to characterize the TFR for gear fault diagnosis. The S transform, which combines the separate strengths of the short-time Fourier transform and wavelet transforms, is chosen to perform the time–frequency analysis of vibration signals from gear. Then, the MPS scheme is applied to extract the discriminative features from the TFR. The promise of MPS is illustrated by performing our procedure on vibration signals measured from a gearbox with five operating states. Experiment results demonstrate the MPS to be a satisfactory scheme for characterizing TFRs for an accurate classification of gear faults.