Fault Feature Extraction Research Articles

A novel adaptive blind deconvolution algorithm: application to feature extraction of weak faults in RV reducer gears

Abstract Aiming at the problem that the non-stationary and nonlinear weak fault signal of RV (rotate vector) reducers is hard to extract fault features due to the influence of noise and transmission paths, as well as the selection of parameters for maximum correlation kurtosis deconvolution (MCKD) relies heavily on manual experience, this article proposes a fault feature extraction method based on parameter adaptive MCKD for the gear faults of RV reducers. Firstly, the sparrow search algorithm combining sine-cosine and Cauchy mutation (SCSSA) is used to adaptively search for the input parameters of MCKD and obtain the signal after deconvolution with the optimal parameters. Secondly, the deconvoluted signal is subjected to ensemble empirical mode decomposition to obtain modal components on different frequency bands. Finally, calculate the multi-scale fuzzy entropy (MFE) of each component, constructing a MFE feature set vector, and input the feature vector into the support vector machine for fault classification and recognition. The experimental analysis and verification results both indicate that the proposed method can adaptively enhance the weak impact components in the gear signals of the RV reducer, effectively extracting weak fault features disturbed by noise. Compared with minimum entropy deconvolution, multipoint optimal minimum entropy deconvolution adjusted and MCKD, the proposed method has improved identification rate by 17.50%, 10.63% and 15.63%, respectively. In addition, in comparison to multiverse optimization and particle swarm optimizatio algorithms, the SCSSA exhibits superior performance when optimizing MCKD parameters, offering faster convergence speed, higher accuracy, and greater robustness.

A Fault Identification Method of Hybrid HVDC System Based on Wavelet Packet Energy Spectrum and CNN

Aiming at the shortcomings of traditional fault identification methods in fault information acquisition, In the scenario of hybrid HVDC transmission system, a new fault identification method is proposed by using wavelet packet energy spectrum and convolutional neural network (CNN), which effectively solves the problem of complex fault feature extraction of hybrid HVDC transmission system. This method effectively improves the accuracy of fault identification. Firstly, tThe frequency-domain characteristics of the fault transient signal are extracted by wavelet packet transform, and the feature differences are reflected in the form of energy spectrum. Secondly, according to the extracted energy feature information, the order of fault line and fault type is identified by CNN. Finally, through example verification and algorithm comparison, it is concluded that, the mentioned model has a strong ability to identify faults, and has strong anti-noise interference and tolerance to transition resistance.

A Lightweight and Efficient Multi-Type Defect Detection Method for Transmission Lines Based on DCP-YOLOv8.

Currently, the intelligent defect detection of massive grid transmission line inspection pictures using AI image recognition technology is an efficient and popular method. Usually, there are two technical routes for the construction of defect detection algorithm models: one is to use a lightweight network, which improves the efficiency, but it can generally only target a few types of defects and may reduce the detection accuracy; the other is to use a complex network model, which improves the accuracy, and can identify multiple types of defects at the same time, but it has a large computational volume and low efficiency. To maintain the model's high detection accuracy as well as its lightweight structure, this paper proposes a lightweight and efficient multi type defect detection method for transmission lines based on DCP-YOLOv8. The method employs deformable convolution (C2f_DCNv3) to enhance the defect feature extraction capability, and designs a re-parameterized cross phase feature fusion structure (RCSP) to optimize and fuse high-level semantic features with low level spatial features, thus improving the capability of the model to recognize defects at different scales while significantly reducing the model parameters; additionally, it combines the dynamic detection head and deformable convolutional v3's detection head (DCNv3-Dyhead) to enhance the feature expression capability and the utilization of contextual information to further improve the detection accuracy. Experimental results show that on a dataset containing 20 real transmission line defects, the method increases the average accuracy (mAP@0.5) to 72.2%, an increase of 4.3%, compared with the lightest baseline YOLOv8n model; the number of model parameters is only 2.8 M, a reduction of 9.15%, and the number of processed frames per second (FPS) reaches 103, which meets the real time detection demand. In the scenario of multi type defect detection, it effectively balances detection accuracy and performance with quantitative generalizability.

Rotor speed signature analysis‐based inter‐turn short circuit fault detection for permanent magnet synchronous machines

AbstractA rotor speed signature analysis‐ (RSSA‐)based inter‐turn short circuit (ITSC) fault diagnostic method is proposed, which is robust with regard to speed‐ and current‐loop bandwidths of permanent magnet synchronous machine (PMSM) drive systems. Conventional ITSC fault detection solutions that rely on current signals or extra devices. Thus, an initial step of investigation on the validity of RSSA is taken for residual insulation capacity monitoring of the ITSC fault at the incipient stage. The Vold–Kalman filtering order tracking method is employed for the real‐time extraction of fault features. Besides, the impact of speed‐ and current‐loop controller bandwidths on ITSC fault diagnosis is also analysed and an Adaline estimator is designed to decouple their impacts. Finally, the effectiveness of the proposed method is verified on a faulty PMSM, which exhibits satisfying results in tracking the degradation of residual insulation, even if the phase currents are significantly distorted due to low switching frequency of the inverter.

PSparseFormer: Enhancing Fault Feature Extraction Based on Parallel Sparse Self-Attention and Multiscale Broadcast Feedforward Block

PSparseFormer: Enhancing Fault Feature Extraction Based on Parallel Sparse Self-Attention and Multiscale Broadcast Feedforward Block

CDTFAFN: A novel coarse-to-fine dual-scale time-frequency attention fusion network for machinery vibro-acoustic fault diagnosis

When the machinery device operates abnormally, it is not sufficient for fault detection only via extracting fault features from a single sensor due to the latent fault information may be scattered across multiple sensors. Multi-sensory fusion techniques with deep learning framework have attracted increasing attention from researchers due to the exploiting and integration of fault information between multiple sensors. Nevertheless, there are two remaining shortcomings in most existing multi-sensory fusion technologies. (1) Most existing fusion methods merely concentrate on conducting multi-sensory information fusion from time-domain or frequency-domain to achieve fault diagnosis, which are often unsatisfactory in the face of strong noise environments. (2) The collaborative fusion between several vibration sensors is generally considered in the past works, whereas the complementary information fusion between multi-sensory vibro-acoustic heterogeneous data are rarely studied. To address these deficiencies, this paper proposes a novel coarse-to-fine dual-scale time-frequency attention fusion network (CDTFAFN) for machinery fault diagnosis, which not only adequately considers the complementary information fusion of vibro-acoustic signal, but also has robust feature learning capabilities in a noisy scenario. Firstly, the signal-to-image encoding unit (SIEU) containing the improved constant-Q non-stationary Gabor transform (ICQ-NSGT) is introduced to convert the collected raw vibro-acoustic heterogeneous signal into time-frequency representation (TFR) and achieve the coarse-grained feature fusion. Secondly, the time-frequency attention feature fusion unit (TFA-FFU) is designed to concurrently learn the fine-grained features at two scales from the low-level fused features which are meaningful for fault diagnosis. Finally, the coarse-to-fine features are sequentially concatenated and fed into softmax classifier to preferably promote the network learning performance and automatically implement fault classification. The performance of the proposed approach is validated against those state-of-the-art results on two groups of multi-sensory vibro-acoustic data in different experimental platforms. Experiment results show that the proposed method with the diagnosis accuracy of 99 % above outperforms other several representative fusion technologies (i.e., 2MNet, MFF-GBFD, MSCNN-BiLSTM, MFAN-VAF, 1D-CNN-VAF, MI-CNN-TFT and TFFN-VAF) in the raw noise-free addition scenario. Moreover, the average testing accuracy of the proposed method can still reach 97 % above in the noisy scenarios with Gaussian white noises, which shows its competitive superiority and strong robustness against noises in machinery fault diagnosis. According to the five ensemble macro-average performance evaluation metrics (i.e., accuracy, precision, sensitivity, specificity and F1-score) and the receiver operator characteristic (ROC) analysis, our findings also emphasize the superiority of applying our method for machinery fault diagnosis under the colored noises compared with other fusion technologies (i.e., 2MNet, MFF-GBFD, MSCNN-BiLSTM, MFAN-VAF, 1D-CNN-VAF, MI-CNN-TFT and TFFN-VAF) reported in this paper.

A hybrid deep learning model towards fault diagnosis of drilling pump

This paper proposes a novel method namely WaveletKernelNet-Convolutional Block Attention Module-BiLSTM for intelligent fault diagnosis of drilling pumps. Initially, the random forest method is applied to determine the target signals that can reflect the fault characteristics of drilling pumps. Accordingly, the WaveletKernelNet-Convolutional Block Attention Module Net is constructed for noise reduction and fault feature extraction based on signals. The Convolutional Block Attention Module embedded in WaveletKernelNet-CBAM adjusts the weight and enhances the feature representation of channel and spatial dimension. Finally, the Bidirectional Long-Short Term Memory concept is introduced to enhance the ability of the model to process time series data. Upon constructing the network, a Bayesian optimization algorithm is utilized to ascertain and fine-tune the ideal hyperparameters, thereby ensuring the network reaches its optimal performance level. With the hybrid deep learning model presented, an accurate fault diagnosis of a real five-cylinder drilling pump is carried out and the results confirmed its applicability and reliability. Two sets of comparative experiments validated the superiority of the proposed method. Additionally, the generalizability of the model is verified through domain adaptation experiments. The proposed method contributes to the safe production of the oil and gas sector by providing accurate and robust fault diagnosis of industrial equipment.

A GA based SVM-Bayesian technique and its application in process monitoring for mixed distributed data

Traditional data-driven fault diagnosis methods, such as principal component analysis (PCA) and independent component analysis (ICA), have significantly improved condition monitoring and fault diagnosis of industrial process by analyzing process data. However, their accuracy is limited due to the assumption that the data follows Gaussian or non-Gaussian distribution, respectively. In reality, process data is often a mixture of both Gaussian and non-Gaussian distributions, leading to reduced accuracy of the training model and fault diagnosis results. To address this issue, a genetic algorithm-based SVM-Bayesian (GSB) scheme is proposed in this paper for feature combination and model integration. The scheme first employs ICA and PCA to extract the independent/principal components of the original data, and then constructs the corresponding fault features for SVM training to obtain basic models. The extraction of fault features are optimized using genetic algorithms based on defined accuracy and diversity functions. During online monitoring, the final diagnosis result is obtained by combining the results of the basic models through Bayesian inference. The effectiveness of the proposed scheme is evaluated using a numerical example and a case study of the Tennessee Eastman process. The results show that the accuracy of fault classification is improved by about 5% compared with traditional methods.

A Novel Method for Rolling Bearing Fault Diagnosis Based on Gramian Angular Field and CNN-ViT.

Fault diagnosis is one of the important applications of edge computing in the Industrial Internet of Things (IIoT). To address the issue that traditional fault diagnosis methods often struggle to effectively extract fault features, this paper proposes a novel rolling bearing fault diagnosis method that integrates Gramian Angular Field (GAF), Convolutional Neural Network (CNN), and Vision Transformer (ViT). First, GAF is used to convert one-dimensional vibration signals from sensors into two-dimensional images, effectively retaining the fault features of the vibration signal. Then, the CNN branch is used to extract the local features of the image, which are combined with the global features extracted by the ViT branch to diagnose the bearing fault. The effectiveness of this method is validated with two datasets. Experimental results show that the proposed method achieves average accuracies of 99.79% and 99.63% on the CWRU and XJTU-SY rolling bearing fault datasets, respectively. Compared with several widely used fault diagnosis methods, the proposed method achieves higher accuracy for different fault classifications, providing reliable technical support for performing complex fault diagnosis on edge devices.

An Enhanced Modeling Framework for Bearing Fault Simulation and Machine Learning-based Identification with Bayesian-optimized Hyperparameter Tuning

Abstract Condition monitoring of rotating machinery offers a salient tool for predictive maintenance on rolling elements, subjected to continuous working loads, wear, fatigue, and degradation. In this study, an enhanced computational tool for bearing fault simulation and feature extraction is proposed. A subsequent identification scheme is realized, through Bayesian optimization of hyperparameters, including support vector classifier (SVC), gradient boosting (GBoost), random forest (RF), extreme gradient boosting (XBoost), light gradient boosting machine (LightGBM), and categorical boosting (CatBoost). The proposed hyperparameter optimization technique stands out from traditional methods by offering a more informed and efficient pathway to optimal performance in predictive maintenance. Utilizing Bayesian optimization for hyperparameter tuning of machine learning models, which has not been extensively explored in this field, our approach demonstrates significant advancements. Typical instances of bearing faults, like inner race, outer race, and ball faults are considered. The analysis relies on extraction of statistical and engineering features form collected response signals, including kurtosis, root mean square, peak, and ridge factor. Highly influential variables are highlighted based on feature selection and importance algorithms, allowing bearing fault classification. We demonstrate that SVC and LightGBM produce over 97% of accuracy at low computational cost. This approach constitutes a scalable and robust framework for similar applications in engineering diagnostics.

Sliding time synchronous averaging based on independent extended autocorrelation function for feature extraction of bearing fault

Extracting fault feature is a key challenge during the early failure stage of bearings due to weak fault components and strong background noises. To solve this problem, an extension operation is introduced, and a novel algorithm called independent extended autocorrelation function is proposed. Subsequently, based on time synchronous averaging, the sliding time synchronous averaging method is developed to further enhance periodic components. The time dimension is added to generate a series of periodic impulses, which is advantageous to directly extract the fault characteristic. Therefore, the presented algorithm is called the sliding time synchronous averaging based on independent autocorrelation function (STSA-IEACF). Numerically simulated signals and two experimental datasets are employed to compare the performance of the STSA-IEACF with the mainstream blind deconvolution methods in fault feature extraction of bearing. The results show that the proposed algorithm performs better than the others in this terms of extracting fault characteristics.

Maximum Gpq–mean deconvolution for the impulsive fault feature enhancement of rolling bearing

Abstract The bearing fault signal is easily obscured by background noise and random shocks in the initial stage. The maximum Gpq–mean deconvolution (MGD) method is proposed to address the challenge of extracting fault feature signals in the presence of impact interference. The use of a nonlinear activation function in MGD enhances the distribution characteristics of the filtered signal. The proposed method adopts a new sparse measurement method, which enhances the sparse measurement capability and solves the problem of the difficulty in extracting periodic fault signals under impact. The superiority of the method in rolling bearing diagnosis is demonstrated through simulation and experimental analyses. In comparison with traditional methods, such as minimum entropy deconvolution (MED), optimal minimum entropy deconvolution adjustment, and maximum correlated kurtosis deconvolution, the proposed method in this paper significantly improves the ability of extracting bearing fault signals.

Fault Diagnosis of Wind Turbine Gearbox Based on Modified Hierarchical Fluctuation Dispersion Entropy of Tan-Sigmoid Mapping.

Vibration monitoring and analysis are important methods in wind turbine gearbox fault diagnosis, and determining how to extract fault characteristics from the vibration signal is of primary importance. This paper presents a fault diagnosis approach based on modified hierarchical fluctuation dispersion entropy of tan-sigmoid mapping (MHFDE_TANSIG) and northern goshawk optimization-support vector machine (NGO-SVM) for wind turbine gearboxes. The tan-sigmoid (TANSIG) mapping function replaces the normal cumulative distribution function (NCDF) of the hierarchical fluctuation dispersion entropy (HFDE) method. Additionally, the hierarchical decomposition of the HFDE method is improved, resulting in the proposed MHFDE_TANSIG method. The vibration signals of wind turbine gearboxes are analyzed using the MHFDE_TANSIG method to extract fault features. The constructed fault feature set is used to intelligently recognize and classify the fault type of the gearboxes with the NGO-SVM classifier. The fault diagnosis methods based on MHFDE_TANSIG and NGO-SVM are applied to the experimental data analysis of gearboxes with different operating conditions. The results show that the fault diagnosis model proposed in this paper has the best performance with an average accuracy rate of 97.25%.

A Fault Diagnosis Method for Analog Circuits Based on Improved TQWT and Inception Model

A soft fault in an analog circuit is a symptom where the parameter range of a component exists symmetrically to the left and right of its nominal value and exceeds a specific range. The proposed method uses the Grey Wolf Optimization (GWO) optimized tunable Q-factor wavelet transform (TQWT) algorithm for feature refinement, the Inception model for feature extraction, and an SVM for fault diagnosis. First, the Q-factor is optimized to make it more compatible with the signal. Second, the signal is decomposed, and a single-branch reconstruction is performed using the TQWT to extract features adequately. Then, fault feature extraction is conducted using the Inception model to obtain multiscale features. Finally, a Support Vector Machine (SVM) is used to complete the entire fault diagnosis process. The proposed method is comprehensively evaluated using the Sallen–Key bandpass filter circuit and the four-op-amp biquad high-pass filter circuit widely used in electronic systems. The experimental results prove that the proposed method outperforms the existing methods in terms of diagnosis accuracy and reliability.

Adaptive Low-Rank Tensor Estimation Model Based Multichannel Weak Fault Detection for Bearings.

Multichannel signals contain an abundance of fault characteristic information on equipment and show greater potential for weak fault characteristics extraction and early fault detection. However, how to effectively utilize the advantages of multichannel signals with their information richness while eliminating interference components caused by strong background noise and information redundancy to achieve accurate extraction of fault characteristics is still challenging for mechanical fault diagnosis based on multichannel signals. To address this issue, an effective weak fault detection framework for multichannel signals is proposed in this paper. Firstly, the advantages of a tensor on characterizing fault information were displayed, and the low-rank property of multichannel fault signals in a tensor domain is revealed through tensor singular value decomposition. Secondly, to tackle weak fault characteristics extraction from multichannel signals under strong background noise, an adaptive threshold function is introduced, and an adaptive low-rank tensor estimation model is constructed. Thirdly, to further improve the accurate estimation of weak fault characteristics from multichannel signals, a new sparsity metric-oriented parameter optimization strategy is provided for the adaptive low-rank tensor estimation model. Finally, an effective multichannel weak fault detection framework is formed for rolling bearings. Multichannel data from the repeatable simulation, the publicly available XJTU-SY whole lifetime datasets and an accelerated fatigue test of rolling bearings are used to validate the effectiveness and practicality of the proposed method. Excellent results are obtained in multichannel weak fault detection with strong background noise, especially for early fault detection.

A strong anti-noise and easily deployable bearing fault diagnosis model based on time–frequency dual-channel Transformer

Deep learning is widely used in Bearing Fault Diagnosis (BFD). Nonetheless, practical industrial production often generates a large amount of industrial noise. These noises exhibit randomness and complexity, which puts forward higher requirements for diagnosis algorithms. Certain studies have tackled the issue of anti-interference in high-noise environments (SNR≤0dB) by increasing the complexity of the model. However, due to the excessive number of parameters and computation, such models cannot be deployed on low-end edge devices. Balancing resource consumption and accuracy has become a major challenge in BFD modeling research. To solve the above problems, this paper proposes a new Transformer architecture model called LTFAFormer. The LTFAFormer is capable of achieving high-precision diagnostics on low-end edge devices and shows greater noise resistance. In terms of processing sequence information, Transformer has proven to be superior to other solutions. However, when dealing with longer sensor signal data containing complex noise, the traditional self-attention mechanism not only cannot effectively extract fault features, but also generates more computational complexity than CNN. To address this issue, we propose a novel time–frequency dual-channel parallel attention mechanism. Our approach enhances the feature extraction capability of the model by expanding the attention computation scale and reduces the computational resource consumption of the model by optimizing the model structure. To validate the effectiveness of LTFAFormer, we present two cases to demonstrate that LTFAFormer has higher prediction accuracy while satisfying lightweight. Especially in high-noise environments, LTFAFormer has stronger robustness. In this paper provides a new set of feasible strategies for the practical deployment of BFD models in practical industrial environments.

Fault modulation mechanism and kinematic modeling of planetary gear with local fault

A planetary gear train involves multiple components and has more complex kinematic relationships than a parallel gear train. Consequently, the fault characteristics extraction is more complicated. To ensure safe operation, it is necessary to properly understand the fault behavior of the planetary gear train. In the previous kinematic modeling, the relationship between the faulty tooth meshing location and the fault impact response phase is not fully considered. However, the fault impact response phase variation plays an important role in accurately characterizing the fault characteristics in the planetary gear train. To solve this problem, we analyze the relationship between the faulty tooth location variation and the fault impact response phase variation and then a novel fault response model is established. Based on this model, a revised planetary damage detection scheme is formulated. Through the simulated data analysis, it is revealed that the faulty tooth location variation not only affects the fault impact response phase, but also reallocates the sideband distributions in the response spectrum. Finally, using a laboratory planetary gear set, it is validated that the proposed model is able to reflect the real damage response better. Therefore, using the proposed model, more accurate damage features are able to be extracted from the measured vibration responses.

Application of an Improved Laplacian-of-Gaussian Filter for Bearing Fault Signal Enhancement of Motors

The presence of strong noise and vibration interference in fault vibration signals poses challenges for extracting fault features from motor bearings. Therefore, appropriate pre-filtering procedures can effectively suppress the impact of the noise interference and further enhance fault-related signals. In this work, an improved Laplacian-of-Gaussian (ILoG) filter is proposed to enhance the fault-related signal. The proposed ILoG approach employs an enhanced Kurtosis-based indicator known as Correlated Kurtosis (CK). The CK capitalizes on the cyclostationarity of fault-related impulses and mitigates the random nature of impulse noise. Subsequently, an objective function, based on CK statistics, is suggested to iteratively update LoG coefficients by maximizing the CK value of the output signal. Therefore, the ILoG filter can better highlight the fault cyclic impulses associated with bearing faults. Furthermore, the ILoG filter is capable of attenuating impulsive noise, a feature that is absent in the original LoG filter. The simulation and experimental results demonstrate that the proposed ILoG method provides a remarkable capability to effectively enhance the fault-induced components, thereby improving the diagnostic accuracy. Consequently, the ILoG filter holds great potential for application in motor bearing fault diagnosis.

A model-data combination driven digital twin model for few samples fault diagnosis of rolling bearings

Abstract Deep learning-based fault diagnosis methods for rolling bearings are widely utilized due to their high accuracy. However, they have limitations under conditions with few samples. To address this problem, a model-data combination driven digital twin model (MDCDT) is proposed in this work for fault diagnosis with few samples of rolling bearings. The simulation signals generated by different fault dynamic models of rolling bearings and the measured signals are mixed through MDCDT. The MDCDT generates virtual signals to bridge the gap between the simulated signals and the measured signals by combining their respective advantages. This paper also proposes image coding method based on the Markov transfer matrix (MTMIC) to convert one-dimensional vibration signals into two-dimensional images with both frequency domain information and time domain information, making it easier to extract fault features in neural network training. In the end, the developed MDCDT was evaluated using real rolling bearing data. Experiments show that the MDCDT can generate virtual data for fault diagnosis, and the fault diagnosis accuracy is significantly improved.

Rolling bearing fault diagnosis based on DRS frequency spectrum image and improved DQN

Deep learning may encounter challenges in fault diagnosis, such as exploration capability, long-term planning, and handling non-deterministic factors. The paper introduces a novel fault diagnosis method for rolling bearings combining deep Q-network (DQN) with discrete random separation (DRS) frequency spectrum images. DRS can be used to separate the deterministic components and random components of the fault signal and extract the fault feature very effectively. The improved DQN incorporates the atrous spatial pyramid pooling module for multiscale contextual fault feature extraction, enhancing diagnosis accuracy. Various deep networks, including convolutional neural network, ResNet18, traditional DQN, and the improved DQN, are employed with different frequency spectrum images (power spectral density, cepstrum, and DRS) for diagnosing bearing faults. Simulation results demonstrate that combining DRS frequency spectrum images with the improved DQN enhances fault diagnosis accuracy across diverse conditions. Generalization tests reveal strong capability of the proposed method in handling conditions different from the training data. Validation tests on difficult-to-diagnose fault data from the CWRU-bearing dataset demonstrate commendable performance of the improved DQN, even on difficult datasets. Finally, validation tests using the XJTU–SY bearing dataset reaffirm the excellent performance and robust adaptability of the improved DQN in conjunction with DRS frequency spectrum images.