Compound Fault Diagnosis Research Articles

Compound fault recognition and diagnosis of rolling bearing in open-set-recognition setting

The established bearing fault diagnosis methods are built to predict fault which is known at training time, leading to false predictions when unknown faults occur. To address this, this paper proposes a novel intelligent fault diagnosis methodology. To detect unknown faults in open-set-recognition (OSR) setting, the developed method proposes the evidential neural network involving two fully connected layers to classify and recognize faults. And a novel evidence prediction function is developed to improve diagnosis performance. To achieve more effective fault diagnosis in OSR setting, rather than unknown fault recognition, a Fourier transform based data augmentation is applied to diagnose the unknown compound fault. The experimental results show superior performance of the method. It’s able to classify new fault with 97% accuracy and diagnose compound faults (that involves previously unknown faults) with impressive 80% accuracy. The proposed method provides industries a new alternative to diagnose rotating equipment faults in open environments.

Research on Compound Fault Diagnosis of Bearings Using an Improved DRSN-GRU Dual-Channel Model

Research on Compound Fault Diagnosis of Bearings Using an Improved DRSN-GRU Dual-Channel Model

Domain reinforcement feature adaptation methodology with correlation alignment for compound fault diagnosis of rolling bearing

In the long-term operation process, rolling bearings often have multiple single faults or cascade faults, which are coupled with each other to form the compound fault. The complex coupling components of compound fault lead to difficultly building a correlation between compound fault feature and fault class. Moreover, for the transfer learning based on domain adaptation, compound fault feature of source domain is pretty different from that of target domain, thus knowledge of source domain is hard to be transferred into the cross-domain unsupervised learning process of target domain. To solve above mentioned problems well, this paper proposes a domain reinforcement feature adaptation methodology with correlation alignment (CA-DRFA) to complete the cross-domain compound fault diagnosis of bearings. Specifically, a deep reinforcement learning model is improved by being combined with the domain adversarial training way, and meanwhile the correlation alignment metrics is adopted to enhance the generalization performance in feature alignment. In addition, two experiments and an engineering application are performed to demonstrate that CA-DRFA outperforms other popular cross-domain fault diagnosis methods in cross cutting condition and speed transfer tasks. Overall, CA-DRFA is able to implement cross-domain compound fault diagnosis with high accuracy, and effectively reduce the cost of labeling target samples.

A comprehensive approach with DTW-driven IMF selection, multi-domain fusion, and TSA-based feature selection for compound fault diagnosis

Fault diagnosis in industrial machinery ensures operational efficiency and prevents downtimes. However, compound faults present a significant challenge due to their complex nature. This manuscript proposes a novel methodology for identifying compound faults, integrating advanced techniques to address the challenges present in existing methods. Firstly, the ICEEMDAN algorithm is employed for signal decomposition, enabling the extraction of noise-free IMFs crucial for identifying fault signatures. A DTW-based selection criteria is introduced to enhance the accuracy of IMF selection. The Bessel Transform is utilized for time–frequency conversion. HU invariant moments are incorporated as image features, and multi-domain feature fusion is implemented to understand compound faults comprehensively. A novel TSA-based feature selection method is proposed to select optimal features from the fused feature set. The methodology’s effectiveness is evaluated through a case study of compound gear-bearing faults. The results demonstrate the superiority of the approach, with a testing accuracy of 99 %.

Domain generalization for machine compound fault diagnosis by Domain-Relevant Joint Distribution Alignment

In machine fault diagnosis, domain generalization methods have gained significant attention due to their advantage in non-requirement of priori target domain distribution. However, they pose great challenges in domain-relevant feature learning and incurs inferior unseen-domain classification when large domain divergence exists. To address this issuse, we propose a novel distribution alignment strategy named DRJDA (Domain-Relevant Joint Distribution Alignment) that matches the domain-joint distribution and domain-relevant distribution for domain generalization fault diagnosis. Specifically, the α-PE divergence is employed to minimize the distribution discrepancy, which is demonstrated to be explicitly derived as the maximum value of a quadratic function. Additionally, a parameter-free plug-and-play data augmentation module that performs feature-level instance mixture and style transfer to increase the generalization ability. Finally, data from the China Light-duty Vehicle Test Cycle (CLTC) tests are used as case studies, and the experiments carried out across 14 different domains prove the proficiency of the proposed DRJDA in learning domain-invariant feature when significant domain divergence exists, indicating its remarkable potential in compound fault diagnosis for industrial machinery.

A Discrimination-Guided Active Learning Method Based on Marginal Representations for Industrial Compound Fault Diagnosis

A Discrimination-Guided Active Learning Method Based on Marginal Representations for Industrial Compound Fault Diagnosis

Application of improved adaptive method of CEEMD and data-drive in fault diagnosis

PurposeThe diagnosis and prediction methods used for estimating the health conditions of the bearing are of great significance in modern petrochemical industries. This paper aims to discuss the accuracy and stability of improved empirical mode decomposition (EMD) algorithm in bearing fault diagnosis.Design/methodology/approachThis paper adopts the improved adaptive complementary ensemble empirical mode decomposition (ICEEMD) to process the nonlinear and nonstationary signals. Two data sets including a multistage centrifugal fan data set from the laboratory and a motor bearing data set from the Case Western Reserve University are used to perform experiments. Furthermore, the proposed fault diagnosis method, combined with intelligent methods, is evaluated by using two data sets. The proposed method achieved accuracies of 99.62% and 99.17%. Through the experiment of two data, it can be seen that the proposed algorithm has excellent performance in the accuracy and stability of diagnosis.FindingsAccording to the review papers, as one of the effective decomposition methods to deal with nonlinear nonstationary signals, the method based on EMD has been widely used in bearing fault diagnosis. However, EMD is often used to figure out the nonlinear nonstationarity of fault data, but the traditional EMD is prone to modal confusion, and the white noise in signal reconstruction is difficult to eliminate.Research limitations/implicationsIn this paper only the top three optimal intrinsic mode functions (IMFs) are selected, but IMFs with less correlation cannot completely deny their value. Considering the actual working conditions of petrochemical units, the feasibility of this method in compound fault diagnosis needs to be studied.Originality/valueDifferent from traditional methods, ICEEMD not only does not need human intervention and setting but also improves the extraction efficiency of feature information. Then, it is combined with a data-driven approach to complete the data preprocessing, and further carries out the fault identification and classification with the optimized convolutional neural network.

Application of group decomposition and 1.5-dimensional spectra to acoustic composite fault diagnosis of rolling bearings

Abstract Under the background of strong noise and mutual interference coupling of each fault, the acoustic compound fault diagnosis of rolling bearing is very challenging。 For the composite fault features which are difficult to be extracted due to strong noise interference and uneven distribution of fault intensity, put forward the optimization of swarm decomposition combined with 1.5-dimensional(1.5-d) spectrum method of acoustic composite rolling bearing fault feature separation. The method firstly uses the composite index to iteratively search for the optimal group decomposition threshold value, the adaptive group decomposition of composite fault acoustic signals is realized by optimal parameter group disassembly, and then selects the sensitive components for the decomposed components, and then further analyzes the envelope signal of the sensitive components to reduce the redundancy components and the noise interference, and selects the 1.5-d spectrum to further analyze the envelope signal, thus realizes the effective separation of the composite faults of the rolling bearings acoustic faults. Rolling bearing simulations and experimental acoustic signals verify the validity of the proposed method, and this work gives a new tool for composite fault diagnosis of revolving machinery.

Compact convolutional transformers- generative adversarial network for compound fault diagnosis of industrial robot

The safe operation of Industrial robots is a major concern in intelligent manufacturing. Accurate compound fault diagnosis is essential to the safe operation of industrial robots, while it is challenging to achieve since the compound fault samples are hard to be collected. Generative adversarial network (GAN) is a useful tool for addressing the data imbalance issue. However, the computation efficiency of GAN in addressing the data imbalance issue has not been investigated. Hence, this study proposes a lightweight GAN named compact convolutional Transformers-GAN (CCT-GAN) to alleviate the data imbalance issue in compound fault diagnosis modelling. Firstly, the feedback current signals collected from the industrial robot are transformed into time-frequency images via continuous wavelet transformation (CWT). Secondly, CCT-GAN is designed to achieve high-quality fake data generation and compound fault diagnosis modelling without large computational costs. Thirdly, the relation between a single fault and the compound fault is considered in the compound fault diagnosis modelling via multi-hot representation to alleviate the data imbalance issue. An experimental study based on the real-world compound fault dataset of industrial robots reveals that the proposed CCT-GAN shows merits in compound fault diagnosis modelling in comparison with the prevailing algorithms. The results indicate that CCT-GAN can performance of compound fault diagnosis when only 100 data samples from each compound fault category are available.

Cyclostationarity blind deconvolution via eigenvector screening and its applications to the condition monitoring of rotating machinery

Maximum second-order cyclostationarity blind deconvolution (CYCBD) is accomplished by maximizing the second-order cyclostationarity of signals through the indicator of second-order cyclostationarity (ICS2). It is a significant method for extracting weak periodic pulses related to bearing faults. However, since the interference spectral lines generated by the interference signals in squared envelope spectrum do not be considered by ICS2, the method can be invalid for certain applications. In addition, when the detected signal contains compound faults, only one fault can be enhanced, and misdiagnosis is easily caused. This article proposes cyclostationarity blind deconvolution via eigenvector screening, abbreviated as ESCYCBD, for fault feature enhancement and extraction of rotating machinery in order to solve these problems. Different from existing deconvolution methods which use the maximum value of the index as a criterion to select the filter coefficients, this method proposes the concept of eigenvector subspace, which contains the optimal eigenvector as filter coefficients that are ignored by CYCBD. Subsequently, the Fourier coefficients related to a series of cyclic frequencies are extended for compound fault signals. Besides, by using the harmonic characteristics of fault features in the envelope spectrum, fault feature recognition and optimal selection are carried out in eigenvector subspaces. At the same time, the concept of signals set is created, by which means different feature modes of different fault can be extracted at one time. The analysis results of simulation signals and experimental data show that the proposed ESCYCBD has robustness and accuracy in extracting fault feature modes, whether it is single fault diagnosis or compound fault diagnosis.

Toward compound fault diagnosis via EMAGAN and large kernel augmented few-shot learning

Bearings are essential in machinery. Damage to them can cause financial losses and safety risks at industrial sites. Therefore, it is necessary to design an accurate diagnostic model. Although many bearing fault diagnosis methods have been proposed recently, they still cannot meet the requirements of high-accurate prediction of bearing faults. There are several challenges in this: 1) In practical settings, gathering sufficient and balanced sample data for training diagnostic network models proves challenging. 2) The damage to bearings in real industrial production sites is not singular, and compound faults are also a huge challenge for diagnostic networks. To address these issues, this study introduces a novel fault diagnosis model called EMALKNet that integrates DCGAN with Efficient Multi-Scale Attention (EMAGAN) and RepLKNet-XL, enhancing the detection and analysis of bearing faults in industrial machinery. This model employs EMAGAN to explore the underlying distribution of raw data, thereby enlarging the fault sample pool and enhancing the model’s diagnostic capabilities; The large kernel structure of RepLKNet-XL is different from the current mainstream small kernel and has stronger representation extraction ability. The proposed method has been validated on the Paderborn University dataset and the Huazhong University of Science and Technology dataset.

A novel simulation-assisted transfer method for bearing unknown fault diagnosis

Abstract Supervised data-driven bearing fault diagnosis methods rely on completed datasets of faults, which can be challenging for signals collected in real engineering. Recognizing unknown faults using a data-driven approach is particularly difficult, as purposefully modeling these faults is complex. To address this challenge, this study proposes a new simulation-assisted transfer bearing unknown fault diagnosis method for realizing unknown compound fault diagnosis of rotating machinery. Firstly, finite element method is used to obtain the compound fault data that does not exist in the historical data, and wavelet packet transform is performed on the simulated and measured signals to enhance the detailed features of the signals. Then, a deep convolutional feature fusion network based on hybrid multi-wavelet spatial attention is constructed to fuse the time-frequency information processed by different wavelet bases. Finally, by integrating the concepts of intra-class splitting and transfer learning, the model is fine-tuned using simulation data to recognize unknown compound faults of rolling bearings. The method validates the simulated signals’ feasibility and the unknown faults’ diagnostic validity under the publicly available rolling bearings dataset. Compared to the comparison methods, the method’s accuracy increased by 2.86%, 2.61%, 5.41%, 4.77%, and 7.07%, respectively.

Separation and Extraction of Compound-Fault Signal Based on Multi-Constraint Non-Negative Matrix Factorization.

To solve the separation of multi-source signals and detect their features from a single channel, a signal separation method using multi-constraint non-negative matrix factorization (NMF) is proposed. In view of the existing NMF algorithm not performing well in the underdetermined blind source separation, the β-divergence constraints and determinant constraints are introduced in the NMF algorithm, which can enhance local feature information and reduce redundant components by constraining the objective function. In addition, the Sine-bell window function is selected as the processing method for short-time Fourier transform (STFT), and it can preserve the overall feature distribution of the original signal. The original vibration signal is first transformed into time-frequency domain with the STFT, which describes the local characteristic of the signal from the time-frequency distribution. Then, the multi-constraint NMF is applied to reduce the dimensionality of the data and separate feature components in the low dimensional space. Meanwhile, the parameter WK is constructed to filter the reconstructed signal that recombined with the feature component in the time domain. Ultimately, the separated signals will be subjected to envelope spectrum analysis to detect fault features. The simulated and experimental results indicate the effectiveness of the proposed approach, which can realize the separation of multi-source signals and their fault diagnosis of bearings. In addition, it is also confirmed that the proposed method, juxtaposed with the NMF algorithm of the traditional objective function, is more applicable for compound fault diagnosis of the rotating machinery.

Adaptive mode decomposition method based on fault feature orientation and its application to compound fault diagnosis of planetary gearboxes

Abstract Planetary gearboxes often experience multiple component failures during service, which can accelerate the degradation and failure of industrial equipment. Accurate separation and identification of multiple faults is an important means of ensuring the safe and stable operation of equipment. However, different faults can interact with each other, along with the influence of background noise, making it challenging to accurately extract faults with relatively weak energy among multiple faults. This difficulty leads to the problems of potential misdiagnosis and underdiagnosis. To address this issue, an adaptive mode decomposition method based on fault feature orientation (AMD-FF) is proposed in this paper. Initially, a fault impact indicator (FII) is constructed based on period-weighted kurtosis of envelope spectral and correlated combination negentropy to effectively characterize the impulsiveness and periodicity of fault features. Furthermore, with the objective of maximizing the FII, an adaptive decomposition of the original signal is designed based on blind convolution theory using a finite-impulse response filter group. Subsequently, a variable weight particle swarm optimization is employed to adaptively optimize the key decomposition parameters. Finally, the data of industrial-grade planetary gear transmission test rig are collected to validate the proposed method for compound fault diagnosis of planetary gearboxes. The results indicate that the AFMD-FF can effectively separate and extract compound faults in planetary gearboxes, demonstrating superior fault separation and diagnostic performance compared to the fault mode decomposition (FMD) and adaptive FMD. This method offers a novel approach to diagnosing compound faults in rotating equipment in industrial scenarios.

Cross-Domain Compound Fault Diagnosis of Machine-Level Motors via Time–Frequency Self-Contrastive Learning

Cross-Domain Compound Fault Diagnosis of Machine-Level Motors via Time–Frequency Self-Contrastive Learning

An intelligent compound fault diagnosis method using generalized zero-shot model of bearing

Abstract Compound fault occurrence has been unpredictable, especially in industrial scenarios where it is difficult to collect a large number of labeled samples for compound fault. Based on this, this paper proposes a generative generalized zero-shot learning(GZSL) model aimed at synthesizing compound fault features through training with single fault samples. These synthesized features are then used for the recognition of compound fault. Firstly, in order to construct an accurate and effective semantic vector, the semantic generation module and discriminator are utilized to generate the semantics of compound fault. Secondly, a feature extraction module based on CNN is designed to extract various fault features from the two-dimensional time-frequency diagram. Finally, a fault semantic matching module is designed to match the feature vectors of compound faults with the generated fault semantic vectors. This enables the identification of unseen compound fault by computing their maximum similarity. The experimental results demonstrate that the proposed method achieved H scores of 75.83 and 69.24 on two real fault datasets, ensuring the correct classification of compound fault to the greatest extent possible.

Semi-Supervised Informer for the Compound Fault Diagnosis of Industrial Robots.

The increasing deployment of industrial robots in manufacturing requires accurate fault diagnosis. Online monitoring data typically consist of a large volume of unlabeled data and a small quantity of labeled data. Conventional intelligent diagnosis methods heavily rely on supervised learning with abundant labeled data. To address this issue, this paper presents a semi-supervised Informer algorithm for fault diagnosis modeling, leveraging the Informer model's long- and short-term memory capabilities and the benefits of semi-supervised learning to handle the diagnosis of a small amount of labeled data alongside a substantial amount of unlabeled data. An experimental study is conducted using real-world industrial robot monitoring data to assess the proposed algorithm's effectiveness, demonstrating its ability to deliver accurate fault diagnosis despite limited labeled samples.

Adaptive resonance demodulation semantic-induced zero-shot compound fault diagnosis for railway bearings

For the challenges of diverse compound faults and low identification accuracy of railway bearings, a new zero-shot diagnosis model based on adaptive resonance demodulation semantic is proposed for the compound fault diagnosis of railway bearings. The model adopts adaptive resonance demodulation to identify the optimal resonance frequency band rich in fault information in bearing signals, and constructs the single and compound fault semantics of samples without separating the compound fault signals, thus improving the interpretability of semantic features. Moreover, spatial Euclidean distance is used to measure the similarity of features and semantics in the mapping space, which enables the identification of unknown compound faults by single faults. Verification through railway bearing data shows that this model effectively improves the compound fault identification accuracy under zero samples and is better than the comparison models. The research results can provide theoretical reference for the research and application of railway bearing fault diagnosis.

Bearing Compound Fault Diagnosis Using Energy-Constrained Swarm Decomposition and Adaptive Spectral Amplitude Modulation

Bearing Compound Fault Diagnosis Using Energy-Constrained Swarm Decomposition and Adaptive Spectral Amplitude Modulation

Intelligent Diagnosis of Compound Faults of Gearboxes Based on Periodical Group Sparse Model

A gearbox compound fault intelligent diagnosis method based on the period group sparse model is proposed for the problem that the fault features are coupled with each other and the fault components are superimposed on each other and difficult to be separated in the gearbox compound fault signal. Firstly, a binary sequence is constructed to embed the fault pulse period as a priori knowledge into the group sparse model to decouple and separate the composite fault signal while maintaining the amplitude and sparsity of the extracted features. Secondly, the wavelet packet energy features of the decoupled signals are extracted to improve the data quality while enhancing the characterization ability of the dictionary in the classification model. Finally, the wavelet packet energy features are imported into the sparse dictionary classification model, and the fault diagnosis is completed by outputting the fault categories using the self-driven characteristics of the data. The results show that the fault identification accuracy using the proposed method is 97%. In addition, the experimental validation under different states and working conditions with different rotational speeds allows the superiority and effectiveness of the algorithm in this paper to be tested and has the feasibility of a practical application in engineering.