Fault Diagnosis System Research Articles

Data Augmentation and Fault Diagnosis for Imbalanced Industrial Process Data Based on Residual Wasserstein Generative Adversarial Network With Gradient Penalty

ABSTRACTIn practical industrial applications, equipment usually operates normally and failures are relatively rare, resulting in serious imbalances in the collected data. This imbalance leads to issues such as overfitting, instability, and poor robustness, significantly reducing the accuracy and stability of fault diagnosis system. To address these challenges, this research proposes a method for imbalanced data augmentation and industrial process fault diagnosis based on improved Generative Adversarial Network (GAN). The method adopts Wasserstein distance with gradient penalty and integrates residual connections into the architecture of the generator. This innovation not only helps improve gradient transfer in the generator, but also significantly enhances the data generation capabilities of the generative model through improving the stability of training. Limited industrial process data is used by a generative model to produce synthetic samples with high similarity and diversity. These high‐quality samples improve fault diagnosis by enriching the imbalanced dataset. Experimental results on two industrial datasets confirm the method's effectiveness in enhancing fault diagnosis performance with limited data.

Feature-weighted Random Forest with Boruta for Fault Diagnosis of Satellite Attitude Control Systems

The performance of random forest (RF) based satellite attitude control system (ACS) fault diagnosis methods is limited by uninformative features in high-dimensional data. To solve this problem, we proposed a feature-weighted random forest with Boruta (FWRFB) based fault diagnosis method is proposed for fault diagnosis of ACSs. Firstly, a Boruta feature selection algorithm is used to obtain a feature set and determine significant feature weights. Subsequently, a novel feature-weighted random forest (FWRF) algorithm is designed, which utilizes feature-weighted random sampling instead of simple random sampling to generate feature subsets in the RF. The FWRFB effectively utilizes the feature information while mitigating noise interference. Finally, a FWRFB-based diagnostic module is developed for online fault diagnosis of ACSs. The effectiveness of the proposed method is verified by the ACS data from a semi-physical simulation platform.

Assumption-based Design of Hybrid Diagnosis Systems

Hybrid diagnosis systems combine model-based and data-driven methods to leverage their respective strengths and mitigate individual weaknesses in fault diagnosis. This paper proposes a unified framework for analyzing and designing hybrid diagnosis systems, focusing on the principles underlying the computation of diagnoses from observations. The framework emphasizes the importance of assumptions about fault modes and their manifestations in the system. The proposed architecture supports both fault decoupling and classification techniques, allowing for the flexible integration of model-based residuals and data-driven classifiers. Comparative analysis highlights how classical model-based and pure data-driven systems are special cases within the proposed hybrid framework. The proposed framework emphasizes that the key factor in categorizing fault diagnosis methods is not whether they are model-based or data-driven, but rather their ability to decuple faults which is crucial for rejecting diagnoses when fault training data is limited. Future research directions are suggested to further enhance hybrid fault diagnosis systems.

Wear fault diagnosis in hydro-turbine via the incorporation of the IWSO algorithm optimized CNN-LSTM neural network

When a hydropower unit operates in a sediment-laden river, the sediment accelerates hydro-turbine wear, leading to efficiency loss or even shutdown. Therefore, wear fault diagnosis is crucial for its safe and stable operation. A hydro-turbine wear fault diagnosis method based on improved WT (wavelet threshold algorithm) preprocessing combined with IWSO (improved white shark optimizer) optimized CNN-LSTM (convolutional neural network-long-short term memory) is proposed. The improved WT algorithm is utilized to denoise the preprocessing of the original signals. Chaotic mapping, bird flock search, and cosine elite variation strategies are introduced to enhance the WSO algorithm's robust performance, and the CNN-LSTM model's hyperparameters are optimized using the IWSO algorithm to improve the diagnostic performance. The experimental results show that the accuracy of the proposed method reaches 96.2%, which is 8.9% higher than that of the IWSO-CNN-LSTM model without denoising. The study also found that the diagnostic accuracy of hydro-turbine wear faults increased with increasing sediment concentration in the water. This study can supplement the existing hydro-turbine condition monitoring and fault diagnosis system. Meanwhile, diagnosing wear faults in hydro-turbines can improve power generation efficiency and quality and minimize resource consumption.

Rub-impact investigation of a bolted joint rotor-bearing system considering hysteresis behavior at mating interface

Hysteresis behavior at the mating interface can induce nonlinear stiffness and frictional dissipation, which may lead to a complex vibration character, self-excited vibration, and even the rubbing fault for the bolted joint rotor system. The present work aims to investigate the effect mechanism of hysteresis behavior on the rotor dynamics and the mechanism of bolted joint performance change induced by a rubbing fault. Firstly, the bolted joint model considering the hysteresis behavior at the mating interface is proposed based on the Iwan model. Then, a non-dimensional dynamic model of the bolted joint rotor system with rubbing fault is established by combining the lumped-mass method and fixed-point rub-impact force model. After that, the nonlinear response of the bolted joint rotor system considering the hysteresis behavior at the mating interface and the effect of rubbing fault on the dynamic performance of such a rotor system is explored. Finally, an experimental verification is carried out by adopting a rotor system test rig with a different stiffness rubbing device. The result shows that the rubbing fault will reduce the critical speed by changing the equivalent average stiffness of the bolted joint and aggravate the self-excited vibration of the system, leading to a stronger nonlinear performance of the rotor system. The outcome of the present work can provide valuable insights into vibration prediction, health detection, and rubbing fault diagnosis for a rotor system with a bolted joint.

Fault tracing in multistage gearbox systems based on an improved transfer path analysis method

This study, has developed a novel structural dynamics decoupling method based on TPA. This approach effectively facilitates fault diagnosis and tracing in multistage gearbox systems. Initially, the research explores the relationship between the transfer function of systems with rigid link decoupling and the coupled system’s frequency response function. Compared with Huangfu et al. (2023) , the signal measurement points are reduced. The MWI (Yu et al., 2023) is employed to solve the inverse problem of bearing force identification. Subsequently, the decoupled frequency response and bearing forces are multiplied to calculate the path contribution, determining the dominant fault transfer path and thereby facilitating fault tracing in gearboxes. The effectiveness of this method is validated through numerical simulations and experimental studies, with fault characteristic enhancement exceeding 200%. To evaluate the method’s universality and robustness, experiments on diverse gearbox systems under varying conditions show enhanced fault characteristics across three fault types, confirming its generalizability.

Complex system fault diagnosis based on interpretive structural model

To realize the fault diagnosis of complex systems, a fault diagnosis method for complex systems based on the explanatory structural model is proposed. According to the fault mechanism analysis, the fault association matrix of system elements is established. The explanatory structural model is applied to transform the fault association relationship of complex systems into an intuitive hierarchical structural model through matrix transformation, so as to realize the structuring and hierarchical propagation of system faults. The PageRank algorithm is introduced to evaluate the influence and impact of system element faults. According to the influence and impact of the same-layer components and the fault transmission logic, the main cause of system fault transmission is clarified, which provides a basis for fault diagnosis. Finally, a specific application is carried out with a certain device as an example to verify the effectiveness of the method.

Enhancing multi-type fault diagnosis in lithium-ion battery systems: Vision transformer-based transfer learning approach

Ensuring the accurate diagnosis of internal short circuit (ISC) faults and consistency anomalies is crucial for maintaining the high safety and longevity of battery systems. The challenge lies in the high similarity between the features of ISC faults and consistency anomalies, which can complicate accurate fault diagnosis. This study introduces a multi-fault diagnostic model that leverages the Vision Transformer (ViT) and employs simulated data to accurately pinpoint ISC faults and intricate consistency anomalies, such as capacity and state of charge anomalies, achieving an impressive accuracy rate of up to 100 %. The process begins with an in-depth analysis of fault mechanisms to extract and differentiate multi-fault features using a mean difference model. Subsequently, the ViT's exceptional ability to capture temporal information, which aids in the accurate identification of fault features. The integration of transfer learning with experimental data further refines the real-world diagnosis accuracy. The results confirm the robustness of the proposed method, highlighting its potential to substantially mitigate safety hazards in battery systems and enhance operational reliability.

Tri-training algorithm based nuclear power systems semi-supervised fault diagnosis under multiple restricted data conditions

An improved tri-training semi-supervised classification method was proposed as a solution to the restricted data conditions of supervised classification models relying on labeled data, semi-supervised models not considering imbalanced proportion of faults data and the presence of faults data with similar feature or varying severity in existing data-driven nuclear power system fault diagnosis studies. Based on the structure of three identical sub-classifiers in the original tri-training algorithm, data update paths have been added, the updated data selection has been strengthened, and the initial information and permissions of sub-models have been differentiated. The novel method only requires the dataset to meet the Smoothness Assumption, and through multiple strict data update paths, it improves the utilization of unlabeled training data while reducing Pseudo-labeling process errors. The difference in permissions and initial information between sub-classifiers is utilized to improve the training rigor for fault types with smaller sample sizes, in order to alleviate the problem of imbalanced data. Based on a marine nuclear power system secondary circuit model and a widely recognized nuclear power plant dataset, multiple nuclear power system common restricted fault diagnosis datasets faced in ships and power plants were obtained to verify the novel method's advantages and generalization. The conclusion is that under the same conditions, compared with the original tri-training method and other semi-supervised learning methods, the Accuracy, AUC, Precision Rate and Recall Rate of the novel method have improved by about 21 %, 10 %, 20 %, and 21 %, respectively, and can reduce about 25 % of misjudgments between similar feature faults.

EMA fault diagnosis method based on multi-information fusion of GRU and improved attention mechanism

Aiming at the problems of time series feature loss and fault information loss in traditional electromechanical servo system (EMA) fault diagnosis methods based on machine learning and deep learning, a multi-information fusion EMA fault diagnosis method based on gated recurrent unit (GRU) and improved attention mechanism is proposed. Firstly, the collected different sensor signals are divided into different channels, and the time series features of each channel signal are extracted by GRU. Then, the self-attention mechanism is introduced to further distinguish the important relationship between different time points of the signal. The multi-channel attention mechanism is further introduced to adaptively fuse the features of different channels, and finally the fault diagnosis is realized through the classifier. The experimental results based on the test bench data set show that: compared with the single sensor model, the diagnosis rate is improved 10%; compared with the model without the introduction of the attention mechanism, the diagnosis rate is improved 5.2%; compared with the classic machine learning, deep learning and the improved algorithm based on deep learning in the past two years, the diagnosis rate of the diagnosis model designed in this paper is 98.5%above, and the diagnosis effect is the best.

Derivative dynamic time warping algorithm with introduced correction for varying load fault diagnosis of nuclear power system steam turbine units

The Derivative Dynamic Time Warping (DDTW) algorithm is improved to address the multi-parameters time series classification problem faced by nuclear power system steam turbine units varying load fault diagnosis. Firstly, the entire load changing process is treated as a single sample rather than multiple time-step-samples. This ensures the complete information on the load changing processes, while avoiding interference from normal data fluctuations during faults. Secondly, Time Series Position Coefficient and Time Series Length Coefficient are proposed to correct the DDTW algorithm from two perspectives: the sequences lengths and the data positions in the sequences. This solves the singularities and timeline scaling problems, thereby preventing interference introduced by data sequences' lengths differences and ''similar data appearing at different times'' problem. The nuclear power system steam turbine unit simulation model was built to obtain load changing processes data under normal and faults statuses. In the varying load fault diagnosis test based on these data, the improved DDTW algorithm achieved an accuracy of 1.38%–12.06% higher than other methods, reaching 87.50%. Finally, The Deep Convolutional Generative Adversarial Networks (DCGAN) model was used to generate data to supplement the limited samples of complete load changing processes, and the accuracy of the novel method increased to 95.51% with the increase of data used to support the comparison.

A multi-rate sensor fusion and multi-task learning network for concurrent fault diagnosis of hydraulic systems

Hydraulic systems are widely used in key modern industrial fields such as mechanical manufacturing, aerospace, and heavy machinery, and their efficient and reliable operation is crucial to ensuring production safety and efficiency. However, hydraulic systems often experience concurrent faults, such as pump failures, valve blockages, pipeline leaks, and fluid contamination, which pose significant challenges to the fault diagnosis in hydraulic systems. This paper introduces a multi-task learning network that deconstructs the challenge of concurrent fault diagnosis into specific sub-tasks, enabling the simultaneous identification and classification of multiple hydraulic components' faults. Automatic channel filtering is designed to screen out sensitive channels of each component from multi-rate sensors. A dual-flow model is used to feature extraction, which can simultaneously extract the local spatial features and global semantic information. Then, four classification models are designed to identify the extracted shared features. An uncertainty weight loss is also proposed to balance the loss of different tasks. The experimental results show that our model significantly outperforms traditional methods and other popular multi-output methods in diagnosing concurrent faults.

Bayesian optimized deep Q-network for diagnosing mine ventilation systems windage alteration fault targeting imbalanced data

Fault diagnosis of mine ventilation system is of great significance for mine safety production. Traditional machine learning algorithms have been widely applied in the field of mine ventilation systems windage alteration faults (WAFs) diagnosis, but these algorithms have poor intelligence and weak generalization ability. Therefore, this research constructs a WAFs diagnosis model (WAFs-BODQN) based on Bayesian optimized (BO) deep Q-network (DQN). Meanwhile, in order to solve the problem of poor performance of intelligent models when the dataset is imbalanced, a reinforcement learning reward function (KMeans-SDF) was designed, which combines the KMeans++ algorithm and spatial distance function (SDF). The WAFs-BODQN model with KMeans-SDF reward function has fault location diagnosis accuracies of 98.75 %, 97.50 %, and 95.00 % for mild, moderate, and extreme imbalanced datasets UB1, UB2, and UB3, respectively. This effectively avoids the "eccentricity" phenomenon of the intelligent model on majority class and achieves accurate prediction of fault locations. The accuracy of fault location diagnosis using the WAFs-BODQN model in simulation experiments and on-site empirical applications is higher than 95 %, demonstrating the intelligence, generalization, and feasibility of WAFs-BODQN model in the field of WAFs diagnosis in mine ventilation systems. By comparing the results with traditional machine learning and deep learning fault diagnosis models, it has been proven that the WAFs-BODQN model has advantages in intelligence and generalization ability. It is expected to establish a universal architecture for diagnosing WAFs, providing theoretical guidance and technical support for achieving intelligent mine ventilation.

Acoustic leak localization for water distribution network through time-delay-based deep learning approach

Water leakage within water distribution networks (WDNs) presents significant challenges, encompassing infrastructure damage, economic losses, and public health risks. Traditional methods for leak localization based on acoustic signals encounter inherent limitations due to environmental noise and signal distortions. In response to this crucial issue, this study introduces an innovative approach that utilizes deep learning-based techniques to estimate time delay for leak localization. The research findings reveal that while the Res1D-CNN model demonstrates inferior performance compared to the GCC-SCOT and BCC under high signal-to-noise ratio (SNR) conditions, it exhibits robust capabilities and higher accuracy in low SNR scenarios. The proposed method's efficacy was empirically validated through field measurements. This advancement in acoustic leak localization holds the potential to significantly improve fault diagnosis and maintenance systems, thereby enabling efficient management of WDNs.

Framework for Data‒Driven Fault Diagnosis of Numerical Spacecraft Propulsion Systems

The increasing complexity of deep space missions introduces significant challenges in maintaining spacecraft health, particularly in the propulsion systems, due to the inherent communication delays with Earth. This research proposes a novel framework for the autonomous, data-driven fault diagnosis of spacecraft propulsion systems. Leveraging data generated from a spacecraft propulsion system simulation model. The study addresses the limitations imposed by computational resources and sensor installation constraints through Sequential Forward Selection (SFS) for optimized sensor placement and feature selection. The framework's effectiveness is demonstrated through implementation on a microcomputer, showing promising results in terms of diagnostic accuracy and processing speed, thus highlighting its potential for onboard spacecraft application. This study not only advances the autonomous capabilities of spacecraft in deep space but also contributes to the broader field of Prognostics and Health Management (PHM) by providing a scalable, efficient approach to fault diagnosis in critical spacecraft systems. The proposed framework demonstrates a promising approach to optimizing diagnostic tasks for spacecraft systems. However, the trade-offs observed necessitate a careful consideration of task-specific requirements and the potential need for adjustments to maintain a high level of accuracy alongside computational efficiency.

Cross-domain transfer fault diagnosis by class-imbalanced deep subdomain adaptive network

In variable working conditions and class imbalances, fault diagnosis in gearbox systems becomes difficult due to the difficulty in learning the classification boundaries of the minority class. Moreover, the diversity in fault mode distributions under various working conditions poses significant challenges for domain adaptation. To this end, this work proposed a Class-imbalanced Deep Subdomain Adaptive Network (CIDSAN) for complex cross-domain fault diagnosis scenarios involving feature and label shifts. We design a convolutional neural network embedded with SimAM (SimAM-CNN) to extract global feature information from time-domain vibration signals. Subsequently, a novel cost-sensitive classifier is presented for class re-weighting, along with a Joint Supervised Classifier that refines intra-class and inter-class distances by re-weighting class weights in the latent space using cost-sensitive classifiers while leveraging LDAM regularization to adjust classification boundaries. Diagnostic case studies on two datasets under various working conditions validate the effectiveness and superiority of the proposed approach. The code https://github.com/Zjy0121/CIDSAN.

Research on fault diagnosis for three-phase rectifier device in direct current transmission system based on continuous wavelet transform and vision transformer

Abstract As a core component of photovoltaic power generation systems, the three-phase rectifier device plays a crucial role, and its failure can potentially reduce energy conversion efficiency and output quality. Presently, the performance of fault time-domain signal diagnosis methods based on three-phase rectifier circuits is challenging to enhance. This paper proposes a novel fault detection method for three-phase rectifier devices based on Vision Transformer, referred to as CWT-ViT, to address this issue. This method transforms time-domain fault signals into images through Continuous Wavelet Transform (CWT), subsequently inputting these images into a Vision Transformer model. Relying on its powerful self-attention mechanism and fully connected layers, it realizes the extraction and learning of rectifier device image features. A Simulink simulation model of a three-phase bridge controllable rectifier circuit is established for fault injection to collect fault signals. Fault diagnosis experiments demonstrate that the proposed diagnostic method achieves a prediction accuracy of 98.6%, maintaining a relatively high precision level. In comparison to four excellent classification models currently available: AlexNet, RepVGG, ResNet, and GoogLeNet, the proposed method demonstrates superior diagnostic performance. Additionally, this paper conducts ablation experiments to meticulously analyze the impact of each module in the fault diagnosis process. This research achieves more precise and efficient fault diagnosis in photovoltaic power generation systems, thereby reducing downtime and maintenance costs for actual equipment and enhancing the stability of photovoltaic power generation systems. This research provides an innovative, intelligent solution for the intelligent operations and maintenance of photovoltaic power generation.

Self-adaptive fault diagnosis for unseen working conditions based on digital twins and domain generalization

In recent years, intelligent fault diagnosis based on domain adaptation has been used to address domain shifts in cyber–physical systems; however, the need for acquiring target data sufficiently limits their applicability to unseen working conditions. To overcome such limitations, domain generalization techniques have been introduced to enhance the capacity of fault diagnostic models to operate under unseen working conditions. Nevertheless, existing approaches assume access to extensive labeled training data from various source domains, posing challenges in real-world engineering scenarios due to resource constraints. Moreover, the absence of a mechanism for updating diagnostic models over time calls for the exploration of self-adaptive generalized diagnosis models that are capable of autonomous reconfiguration in response to new unseen working conditions. In such a context, this paper proposes a self-adaptive fault diagnosis system that combines several paradigms, namely Monitor-Analyze-Plan-Execute over a shared Knowledge (MAPE-K), Domain Generalization Network Models (DGNMs), and Digital Twins (DT). The MAPE-K loop enables run-time adaptation to dynamic industrial environments without human intervention. To address the scarcity of labeled training data, digital twins are used to generate supplementary data and continuously tune parameters to reflect the dynamics of new unseen working conditions. DGNM incorporates adversarial learning and a domain-based discrepancy metric to enhance feature diversity and generalization. The introduction of multi-domain data augmentation enhances feature diversity and facilitates learning correlations among multiple domains, ultimately improving the generalization of feature representations. The proposed fault diagnosis system has been evaluated on three publicly available rotating machinery datasets to demonstrate its higher performance in cross-work operation and cross-machine tasks compared to other state-of-the-art methods.

Reducing neural network complexity via optimization algorithms for fault diagnosis in renewable energy systems

This article discusses the challenges involved in diagnosing faults in renewable energy systems. A significant challenge is the high computational demands of the artificial intelligence algorithms needed for grid-connected photovoltaic (GCPV) and wind energy conversion (WEC) systems in fault diagnosis. To address this issue, several methods are proposed to reduce computation time, minimize memory requirements, and improve efficiency. First, optimization algorithms such as the Salp Swarm Algorithm (SSA), Genetic Algorithm (GA), and Particle Swarm Optimization (PSO), combined with machine learning classifiers for feature selection, are suggested to reduce computational time and memory space requirements. This approach notably decreases computation time but has a limited impact on memory space. Secondly, further reduction in memory space requirements is recommended by using the variogram method for data reduction. This method can leverage the outputs of preceding algorithms to optimize renewable energy systems, making their operations cost-effective and efficient. Finally, the outputs of the variogram are used to train neural network (NN), recurrent neural network (RNN), and long short-term memory (LSTM) classifiers to differentiate between various modes of operation in GCPV and WEC systems. Experimental results demonstrate the effectiveness and robustness of the proposed methods, showing that memory space can be reduced by 1.3 to 5.6 times and CPU time by 1.1 to 11 times while maintaining accuracy and improving efficiency compared to conventional algorithms.

Fault diagnosis based on incomplete sensor variables with a hierarchical semi-supervised Gaussian mixture classifier

We propose a hierarchical semi-supervised variational semi-Bayesian Gaussian mixture classifier based on the partially incomplete and unlabeled samples for the fault diagnosis of mechanical and electrical systems. These systems are typically complex in structure and are monitored by multiple sensors simultaneously. Some sensor variables in the collected data may be incomplete due to sensor malfunctions or transmission errors. Additionally, labeling the data can be a time-consuming and labor-intensive task, resulting in many unlabeled samples. To address these challenges, the missing sensor variables and the unavailable labels are treated as hidden values and handled within the framework of the Expectation Maximization algorithm. We employ a semi-Bayesian technique with variational inference to estimate the model parameters. Specifically, we introduce prior distribution to the mean and covariance matrix to address the possible singularity of the empirical covariance matrix. The weighting coefficients are left without putting prior distribution so that their values can decay to zero, effectively removing redundant components of the mixture model. The factorized distribution is utilized to approximate the posterior distribution of the model parameters, as well as the missing labels and other latent variables. Numerical and real case studies are carried out to verify the effectiveness of the proposed technique.