Equipment Fault Research Articles

Named entity identification method for manufacturing equipment faults based on improved Roberta

Abstract The recognition of manufacturing equipment fault named entities, as the foundation for constructing knowledge graphs in the field of fault diagnosis, has become an efficient identification method in fault diagnosis research. However, traditional methods for recognizing equipment fault named entities have shown insufficient performance in identifying professional vocabulary entities. This paper proposes a model for recognizing manufacturing equipment fault entities, which replaces the traditional Roberta model with the Roberta-wwm pre-trained model based on whole-word masking. The model improves its grasp of contextual information by integrating a bidirectional long short-term memory network and incorporating a multi-head attention mechanism to capture intricate interdependencies among fault entities in manufacturing equipment, and further optimizes the model’s performance. Experimental data from a large volume of fragmented fault texts generated during the operation and maintenance of certain resistance production equipment are used for validation. Through experiments, the F1 score for manufacturing equipment entity recognition is maximally increased by 2.58%, with evaluation metrics showing an F1 score of 98.76%, precision of 98.84%, and recall of 98.73%. This model provides an efficient and accurate solution for handling manufacturing equipment fault texts.

DIAGNOSIS OF ROLLING BEARING DEFECTS BASED ON WAVELET ANALYSIS

Purpose. Development and improvement of a method for analyzing vibration signals from rolling bearings based on wavelet analysis for the detection and identification of equipment defects. Research methods. Wavelet analysis was employed for processing vibration signals from rolling bearings. Threshold wavelet filtering was applied to highlight weak impulse components in the signals, and Morlet wavelet was used to ensure effective filtration. Results. The research results indicate that the proposed method, utilizing wavelet filtering, enhances the speed and reliability of vibration diagnostics for bearings. This allows for the efficient extraction of characteristic frequencies associated with various types of rolling bearing defects. In comparison with other signal analysis methods, the use of the developed method based on continuous wavelet analysis has proven to be particularly effective in extracting characteristic diagnostic frequencies. This method not only allows for the identification of specific types of defects in rolling bearings but also ensures universality, enabling its successful application for analyzing other types of non-stationary signals. Experimental studies have confirmed the high efficiency of the developed method, especially in the early stages of defect development. The application of this method is evident not only in its ability to effectively highlight the characteristic frequencies of bearings but also in its capacity to conduct signal analysis for the identification of equipment defects as a whole. This makes the proposed method a promising and versatile tool for the diagnosis and monitoring of the condition of technical systems. Scientific novelty. Application of the proposed method for processing vibration signals from rolling bearings based on wavelet analysis to improve the effectiveness of defect detection and identification in equipment. Practical value. The developed method can be applied in the industrial sector for the analysis and diagnostics of rolling bearings in equipment. It enables the timely detection of defects, reduces the risk of equipment failure, and lowers operational maintenance costs. Thus, this method has practical value in enhancing the reliability and productivity of industrial equipment.

Development of a Hybrid AI Model for Fault Prediction in Rod Pumping System for Petroleum Well Production

Rod pumping systems are widely used in oil wells. Accurate fault prediction could reduce equipment fault rate and has practical significance in improving oilfield production efficiency. This paper analyzed the production journal of rod pumping wells in block X of Xinjiang Oilfield. According to the production journal, oil well maintenance operations are primarily caused by five types of faults: scale, wax, corrosion, fatigue, and wear. These faults make up approximately 90% of all faults. 1354 oil wells in the block that experienced workover operations as a result of the aforementioned factors were chosen as the research objects for this paper. To lower the percentage of data noise, wavelet threshold denoising and variational mode decomposition were used. Based on the bidirectional long short-term memory network, an intelligent model for fault prediction was built. It was trained and verified with the help of the sparrow search algorithm. Its efficacy was demonstrated by testing various deep learning models in the same setting and with identical parameters. The results show that the prediction accuracy of the model is the highest compared with other 11 models, reaching 98.61%. It is suggested that the model using artificial intelligence can provide an accurate fault warning for the oilfield and offer guidance for the maintenance of the rod pumping system, which is meant to reduce the occurrence of production stagnation and resource waste.

An Intelligent Framework of Equipment Fault Diagnosis Based on Knowledge Graph

Equipment fault information typically exhibits the characteristics of fragmentation and diversified structure. The existing fault diagnosis methods are incapable of fully exploiting the prior knowledge and expert knowledge within the field, and the diagnosis results are overly one-sided. Given that it is challenging to obtain effective fault diagnostic knowledge for complex equipment and complex faults, this paper proposes the application of the domain knowledge graph (KG) for fault diagnosis. Different from the existing fault diagnosis methods involving the KG, our framework consists of two major parts. The first part is to construct an equipment fault KG from semi-structured and unstructured text. We further enrich the graph knowledge through knowledge completion, which can furnish high-quality knowledge sources for downstream applications. The second part is to employ the built fault KG either online or offline for fault diagnosis. We offer two approaches: the deep learning plus KG approach; the question-answering approach. The former not only guarantees the diagnostic accuracy but also provides more comprehensive diagnostic information. This constitutes the online utilization of the KG. The latter realizes the offline use of the KG, providing users with a natural and user-friendly manner to retrieve fault diagnosis information. We demonstrate and verify our proposed framework in the context of the bearing fault diagnosis.

Mechanical equipment fault diagnosis method based on improved deep residual shrinkage network.

Fault diagnosis of mechanical equipment can effectively reduce property losses and casualties. Bearing vibration signals, as one of the effective sources of diagnostic information, are often overwhelmed by substantial environmental noise. To address this issue, we present a fault diagnosis method, CCSDRSN, which exhibits strong noise resistance. This method enhances the soft threshold function in the traditional deep residual shrinkage network, allowing it to extract useful information from the fault signal to the maximum extent, thus significantly improving diagnostic accuracy. Additionally, we have developed a novel activation function that can nonlinearly transform the time frequency map across multiple dimensions and the entire region. In pursuit of network optimization and parameter reduction, we have strategically incorporated depthwise separable convolutions, effectively replacing conventional convolutional layers. This architectural innovation streamlines the network. By verifying the effectiveness of the proposed method using Case Western Reserve University datasets, the results demonstrate that the proposed method not only possesses strong noise resistance in high noise environments but also achieves high diagnostic accuracy and good generalization performance under different load conditions.

Fault Diagnosis Method for Marine Electric Propulsion Systems Based on Zero-Crossing Tacholess Order Tracking

In marine electric propulsion systems (MEPS) driven by variable-frequency drives, motor current signals often exhibit complex modulation components, ambiguous spectra, and severe noise interference, rendering it challenging to extract fault-related modulation components. To address this issue, we propose a zero-crossing tacholess order tracking method based on motor current signals. This method utilizes zero-crossing estimation of the instantaneous frequency to perform angular resampling of stator current signals and demodulates the envelope spectrum to extract fault characteristic spectra, enabling the diagnosis of mechanical faults in MEPS. Given the synchronization of the synchronous motor speed with the inverter fundamental frequency, this method estimates instantaneous frequencies in the time domain without requiring integration or time–frequency representation, which is simple and computationally efficient. Data validation on a small-scale marine electric propulsion test platform demonstrates that the proposed method exhibits good robustness under variable-speed conditions and effectively detects imbalance faults caused by propeller breakages and gear faults resulting from bevel gear tooth defects. Therefore, the proposed method can be applied to diagnose faults in downstream mechanical equipment driven by motors.

Learning-based production, maintenance, and quality optimization in smart manufacturing systems: A literature review and trends

With the introduction of manufacturing paradigms, including Industry 4.0, production research has shifted its focus to enabling intelligent manufacturing systems within industrial environments. These systems can efficiently schedule and control processes and operations using artificial intelligence methods, including machine learning and deep learning. Since 1995, relevant literature has presented several examples of such implementations, addressing topics, for example equipment fault diagnosis and quality inspections. To this end, the present paper strives to present a state-of-the-art review of the learning-based scheduling and control frameworks, which are exploited in the production research. The review is limited to the relevant research between the years 1995 and 2024, surveying approaches in the domains of manufacturing, maintenance, and quality control. To this end, the paper follows a meta-analysis method for the selection and evaluation of relevant research articles. Moreover, research questions are formulated to analyze the obtained findings and seek out insights on aspects of the relevant research, including the inclusion of decision-making models and dissemination of literature. The provided answers, among others, reveal trends and limitations of the state-of-the art research in relation to learning-based scheduling and control.

Upper limit assessment of GIS equipment failure based on time series model and deep learning algorithm

If a sudden fault of gas-insulated switchgear is not handled in time, it will delay production and cause certain economic losses to the enterprise. Therefore, this study proposes an upper limit assessment algorithm for equipment faults based on time series model and deep learning. The irregular fluctuation components in the time series model are stabilized by using empirical mode decomposition, and the long short-term memory network in the deep learning algorithm is introduced to combine the two. The equipment fault data is obtained by the joint algorithm. After empirical mode decomposition, the intrinsic mode function component of the data signal is obtained, and the sensitive component is extracted from it. The relationship value and mutual information between it and the original data signal are analyzed to complete the fault data feature extraction. In the process of equipment fault upper limit assessment, the parameter optimization and convergence are controlled, and the fault deep learning model is constructed. After the refraction coefficient and reflection coefficient are determined, the upper limit assessment of equipment faults is realized. The proposed method is experimentally tested. The results show that the proposed algorithm has an ideal upper limit assessment result of faults, and the obtained curve has a high degree of fit with the actual result curve. It can be proved that the proposed algorithm can scientifically evaluate the upper limit of equipment faults and has certain application value.

Efficient Fault Warning Model Using Improved Red Deer Algorithm and Attention-Enhanced Bidirectional Long Short-Term Memory Network

The rapid advancement of industrial processes makes ensuring the stability of industrial equipment a critical factor in improving production efficiency and safeguarding operational safety. Fault warning systems, as a key technological means to enhance equipment stability, are increasingly gaining attention across industries. However, as equipment structures and functions become increasingly complex, traditional fault warning methods face challenges such as limited prediction accuracy and difficulties in meeting real-time requirements. To address these challenges, this paper proposes an innovative hybrid fault warning method. The proposed approach integrates a multi-strategy improved red deer optimization algorithm (MIRDA), attention mechanism, and bidirectional long short-term memory network (BiLSTM). Firstly, the red deer optimization algorithm (RDA) is enhanced through improvements in population initialization strategy, adaptive optimal guidance strategy, chaos regulation factor, and double-sided mirror reflection theory, thereby enhancing its optimization performance. Subsequently, the MIRDA is employed to optimize the hyperparameters of the BiLSTM model incorporating an attention mechanism. A predictive model is then constructed based on the optimized Attention-BiLSTM, which, combined with a sliding window approach, provides robust support for fault threshold identification. The proposed algorithm’s efficacy is demonstrated through its application to real-world gas-fired power plant equipment fault cases. Comparative analyses with other advanced algorithms reveal its superior robustness and accuracy in efficiently issuing fault warnings. This research not only provides a more reliable safeguard for the stable operation of industrial equipment but also pioneers a new avenue for the application of metaheuristic algorithms.

Research on Chebyshev Graph Convolutional Neural Network Modeling Method for Rotating Equipment Fault Diagnosis under Variable Working Conditions

Given the challenges of rotating equipment fault diagnosis under variable working conditions, including the unbalanced transmission of information during feature extraction, difficulty in capturing both global and local features, and limited generalization across different working conditions, a Chebyshev graph convolutional neural network (ChebyNet) method is proposed to address these issues. First, a symmetry processing mechanism is incorporated into the framework of the ChebyNet to balance the transfer of information between nodes in the graph to ensure the fair and efficient integration of information. Secondly, the wide-area feature extraction capabilities of the ChebyNet and the adaptive nodes of the graph attention network (GAT) are integrated to achieve the comprehensive mining of fault characteristics and accurate characterization of complex interactive relationships. Finally, the node reconstruction task of self-supervised learning and collaborative node classification tasks are used to enhance the model’s ability to capture complex changes in variable working conditions data, significantly improving the generalizability of working conditions. In comparative and cross-validation experiments, the proposed method achieved an average diagnostic accuracy of 99.72%, representing an improvement of up to 17.96% compared to other graph neural network (GNN) models. It significantly enhances the accuracy, stability, and generalization of fault diagnosis. Ablation experiments further validate the effectiveness of the proposed method in improving fault diagnosis performance under variable working conditions.

Research on Denoising Algorithm of Standpipe Pressure Signal in FCC Device Based on Tortuosity and Denoising Intensity.

The pressure signal of the standpipe in the regeneration device for the catalytic cracking reaction is commonly used as a basis for equipment fault diagnosis. The device operates in environments of high temperature, strong vibration, and high flow rate. The standpipe pressure signal is easily interfered with by noise, making it difficult to extract pressure characteristics. In this study, a signal denoising algorithm based on pressure curve tortuosity and denoising intensity is proposed. A power spectrum threshold vector is utilized to filter the pressure in the circulating standpipe, and the denoising intensity and tortuosity after denoising are calculated. Taking the ratio of noise reduction intensity and tortuosity as the objective function, the noise reduction scheme of the pressure signal at different heights of the standpipe is determined. The denoised pressure signals are reconstructed, and the characteristic pressure signals of the circulating standpipe are extracted. The results indicate that the method suppressed the noise, enhanced the significance of characteristic parameters, and improved the accuracy of the fault diagnosis in the FCC units.

Bearing fault diagnosis based on enhanced Canberra distance feature in SDP image

Abstract Feature enhancement is important in mechanical equipment fault diagnosis. A limited set of characteristic parameters is insufficient for diagnosing bearing signals with multiple fault types. The presence of noise increases the difficulty of extracting fault features from images. To address the challenge of diagnosing rolling bearing faults in complex environments, this study presents an enhanced weighted image fusion framework aimed at enhancing fault features within the images, which enables accurate diagnosis of bearing faults using a limited number of features. The proposed method encompasses four distinct stages. In the first stage, a symmetrized dot pattern method is employed to transform one-dimensional time-series data into two-dimensional images, visualizing the signal in a 2D format. In the second stage, image binarization and an improved weighted fusion method are utilized to simplify subsequent processing and enhance the image features. The third stage involves extracting the image’s contrast and maximum singular value to improve the Canberra distance calculation. Finally, the enhanced Canberra distance is used for classifying bearing faults. Performance testing of the image feature enhancement is conducted on various datasets containing rolling bearings. Comparative experiments with alternative enhancement methods demonstrate the superiority of the proposed improved weighted image fusion framework. Comparative experiments with the original Canberra distance validate the effectiveness of the enhanced Canberra distance. Additionally, experiments conducted in noisy environments confirm the robustness of the proposed approach. Furthermore, the image feature enhancement method is applied to other bearing datasets, and the experimental results demonstrate its effectiveness in enhancing fault feature representation and achieving accurate diagnosis of rolling bearings.

Classification of The Analog Informative Parameters of the Rod Deepwell Pump Dynamograph Signals

In mechanized oil production, rod deep-well pumps are widely used. They consist of surface and underground parts. The above-ground part includes pump drive and wellhead fittings. The wellhead fitting is designed to seal the well. The underground part is the pump itself. The pump consists of a plunger, rod string and tubing. The main method of diagnosing a rod deep-well pump is dynamometry. Dynamometry allows to determine the equipment defects and control the efficiency of the pump operation mode without stopping the well operation. Dynamometry is a process of measuring the loads, which are perceived by the polished rod during the operation of the well. There are theoretical and practical dynamograms. Practical dynamogram is a closed non-periodic curve with variable amplitude. There are various methods to automate the process of the dynamometry result processing. In this paper we analyze the analog informative parameters of dynamometer signals. These parameters depend on the friction forces in the underground part of the rod pump, inertial forces, tightness of valve assemblies, dynamic liquid level, etc. The results obtained can be used in the development of the pumping process. The obtained results can be also applied to develop processing algorithms of practical dynamograms.

Power equipment defect prediction based on time series knowledge graph

With the increasing scale of power facilities, the operation monitoring of power equipment has become an important part of power system management. Defect prediction of power equipment is a key step in power system operation monitoring. In order to solve the problem of defect prediction of power equipment in large-scale power systems, this paper proposes a power equipment defect prediction model based on time series knowledge graph in combination with artificial intelligence technology. Multimodal information is fused through the attention mechanism, and then the time series representation of entities and relations is obtained by using the relationship-aware graph neural network and recurrent neural network. Finally, the defects of power equipment are predicted based on the time series representation. The method proposed in this paper can make full use of multimodal information and improve the accuracy of power equipment defect prediction. Experiments show that the performance of the model proposed in this paper is better than that of the baseline model.

Named Entity Recognition for Equipment Fault Diagnosis Based on RoBERTa-wwm-ext and Deep Learning Integration

Equipment fault diagnosis NER is to extract specific entities from Chinese equipment fault diagnosis text, which is the premise of constructing an equipment fault diagnosis knowledge graph. Named entity recognition for equipment fault diagnosis can also provide important data support for equipment maintenance support. Equipment fault diagnosis text has complex semantics, fuzzy entity boundaries, and limited data size. In order to extract entities from the equipment fault diagnosis text, this paper presents an NER model for equipment fault diagnosis based on RoBERTa-wwm-ext and Deep Learning network integration. Firstly, this model uses the RoBERTa-wwm-ext to extract context-sensitive embeddings of text sequences. Secondly, the context feature information is obtained through the BiLSTM network. Thirdly, the CRF is combined to output the label sequence with a constraint relationship, improve the accuracy of sequence labeling task, and complete the entity recognition task. Finally, experiments and predictions are carried out on the constructed dataset. The results show that the model can effectively identify five types of equipment fault diagnosis entities and has higher evaluation indexes than the traditional model. Its precision, recall, and F1 value are 94.57%, 95.39%, and 94.98%, respectively. The case study proves that the model can accurately recognize the entity of the input text.

Fault Diagnosis of Maritime Equipment Using an Intelligent Fuzzy Framework

The task of automatically and intelligently diagnosing faults in marine equipment is of great significance due to the numerous duties that shipboard professionals must handle. Incorporating automated and intelligent systems on ships allows for more efficient equipment monitoring and better decision-making. This approach has attracted considerable interest in both academia and industry because of its potential for economic savings and improved safety. Several fault diagnosis methods are documented in the literature, often involving mathematical and control theory models. However, due to the inherent complexity of some processes, not all characteristics are precisely known, making mathematical modeling highly challenging. As a result, fault diagnosis often depends on data or heuristic information. Fuzzy logic theory is particularly well suited for processing this type of information. Therefore, this paper employs fuzzy models to diagnose faults in a marine pneumatic servo-actuated valve. The fuzzy models used in fault diagnosis are obtained from the data. These fuzzy models are identified for the normal operation of the marine pneumatic servo-actuated valve, and for each fault, predicting the system’s outputs from the inputs and outputs of the process. The proposed fault diagnosis framework analyzes the discrepancy signals between the outputs of the fuzzy models and the actual process outputs. These discrepancies, known as residuals, help in detecting and isolating equipment faults. The fault isolation process uses an intelligent decision-making approach to determine the specific fault in the system. This method is applied to diagnose abrupt faults in a marine pneumatic servo-actuated valve. The approach presented was used to detect and diagnose three very important faults in the operation of a marine pneumatic servo-actuated valve. The three faults were correctly detected and isolated, and no errors were detected in this detection and isolation process.

THE INFLUENCE OF DATA SAMPLING ON SOLVING THE PROBLEM OF PATTERN RECOGNITION FOR DIAGNOSTICS OF INDUSTRIAL EQUIPMENT

With the sophisticated technology that modern industrial organizations are equipped with, state prediction and diagnostics are essential duties. The current research aims to develop a more accurate modified artificial intelligence system for industrial equipment diagnostics in the oil and gas industry. Researching faulty signals and processing methods utilized by equipment in the oil and gas industry, as well as assessing the advantages and disadvantages of different signal extraction strategies, are the first steps in the process. The second is the application of artificial intelligence to decision-making and equipment defect detection. This method widely used by the oil and gas sectors to lower equipment failure rates. The recommended diagnostic system helps organizations reduce the financial risks associated with equipment defects by increasing production dependability, enabling for maintenance planning, predicting probable failures, and expediting equipment repairs. The article is devoted to the study of the data sampling influence on the classifier’s predictive ability in diagnosing of the industrial equipment. Various types of data samples were considered, such as: simple random sample, cluster sample, systematic sample. According to the results of listed data samples were built classifiers based on particle swarm optimization and ensemble models (bagging and voting type). The best results were achieved using the systematic sampled dataset and an ensemble modeling strategy with voting, which combines forecasting based on a neural net, gradient boosted trees and naive Bayes models: accuracy 93.6%; classification error 8%; recall 94.32%; precision 93.87%. The resulting best strategy for diagnosing equipment based on data sampling and an ensemble model was used for implementation in FMEA (Failure Mode and Effects Analysis) technology in order to obtain an improved version, which is adapted for working with big data.

Computer Simulation and Simulation of Mechanical and Electrical Equipment based on Artificial Intelligence Algorithms

The computer in mechanical and electrical equipment can now detect equipment faults through simulation thanks to the advancement of artificial intelligence (AI) technology, which makes it convenient to monitor mechanical and electrical equipment. This paper begins with a quick introduction to Agent and the Agent system, explains how Agent is applied in the current context, then analyzes the hierarchical fault diagnostic model, identifies its flaws, and suggests improvement techniques. To increase the model’s accuracy and speed of operation, the contract net model and D-S (Dempster-Shafer) evidence theory are then incorporated. Finally, simulation experiments are used to confirm the accuracy and consistency of this model. According to the experimental findings, this optimization model runs at a pace that is noticeably faster than that of other models when subjected to the same workload, demonstrating the model’s efficacy. Models 1, 2, and 3 are put side by side to demonstrate how clearly multi-task processing may cut down on the model’s running time. In the second experiment, samples of mechanical and electrical equipment defect data are taken from two groups. The results of the comparative experiments demonstrate that the optimized model in this work can be reliable up to a maximum of 0.91 and a minimum of 0.63. It is demonstrated that the model in this work is rational by the fact that among the four types of fault prediction, the optimized model’s reliability is significantly greater than the traditional model’s. The research described in this publication therefore has some reference value for computer simulation of electromechanical equipment.

Research on Typical Fault Diagnosis of Gear based on GHM Multiwavelet Transform and MCKD Algorithm

Background: Gear is the key part of the transmission part of mechanical equipment, which has a high failure rate under complex working conditions or long-term operation, directly affecting the reliability of mechanical equipment. To realize online monitoring of gears and predict gear faults, whether the diagnosis of typical gear faults is accurate and timely is a key link, so it is necessary to study the diagnosis of typical gear faults. Objective: This paper aims to propose a method that can effectively diagnose typical faults of gears and is easy to program, which is beneficial to realize online monitoring of rotating machinery equipment faults. Method: A typical gear fault diagnosis method based on GHM multiwavelet transform and maximum correlation kurtosis deconvolution algorithm (MCKD) is proposed in this paper. The measured vibration signal is decomposed into components with multiple scale spaces and frequency bands through the GHM multiwavelet transform. Then, the MCKD algorithm is run to suppress the noise of GHM multiwavelet transform coefficients, and the periodic components containing fault information are retained and reconstructed. The typical faults such as gear pitting and broken teeth are tested. Results: GHM multiwavelet transform combined with MCKD algorithm can accurately locate the frequency band containing fault information from the vibration signal with multiple modulations, double sideband, and multi-frequency interference and effectively extract the fault frequency and its frequency multiplication. The root means a square error of the extracted fault frequency is 0.08. This method has a good noise suppression effect and high accuracy in extracting fault frequency. Conclusion: The method proposed in this paper is helpful in realizing automatic programming of gear fault diagnosis and is of great significance in realizing real-time monitoring and online diagnosis of rotating machinery equipment faults. More related patents will appear in the future.

Study on Fault Prediction Method of Hydropower Equipment Based on Equipment Health State Detection

Abstract With the continuous development of China’s electric power industry, the installed capacity of power plants is increasing, and hydropower units are developing in the direction of large capacity and high efficiency. As the complexity of the equipment is getting higher and higher, different equipment are more and more different, showing different characteristics when faults occur, which puts forward higher requirements for the safe and stable operation of hydropower units. In response to the above problems, this paper develops a set of human-machine closed-loop remote fault diagnosis reasoning machine system with self-learning function and a set of equipment health state monitoring and prediction system. This remote fault diagnosis system reasoning machine system can reduce the cost of unit equipment fault diagnosis, improve the diagnosis efficiency, and ensure the safe, stable and economic operation of the unit.