Fault Diagnosis Method Research Articles

Wind Turbine Bearing Failure Diagnosis Using Multi-Scale Feature Extraction and Residual Neural Networks with Block Attention

Wind turbine rolling bearings are crucial components for ensuring the reliability and stability of wind power systems. Their failure can lead to significant economic losses and equipment downtime. Therefore, the accurate diagnosis of bearing faults is of great importance. Although existing deep learning fault diagnosis methods have achieved certain results, they still face limitations such as inadequate feature extraction capabilities, insufficient generalization to complex working conditions, and ineffective multi-scale feature capture. To address these issues, this paper proposes an advanced fault diagnosis method named the two-stream feature fusion convolutional neural network (TSFFResNet-Net). Firstly, the proposed method combines the advantages of one-dimensional convolutional neural networks (1D-ResNet) and two-dimensional convolutional neural networks (2D-ResNet). It transforms one-dimensional vibration signals into two-dimensional images through the empirical wavelet transform (EWT) method. Then, parallel convolutional kernels in 1D-ResNet and 2D-ResNet are used to extract multi-scale features, respectively. Next, the Convolutional Block Attention Module (CBAM) is introduced to enhance the network’s ability to capture key features by focusing on important features in specific channels or spatial areas. After feature fusion, CBAM is introduced again to further enhance the effect of feature fusion, ensuring that the features extracted by different network branches can be effectively integrated, ultimately providing more accurate input features for the classification task of the fully connected layer. The experimental results demonstrate that the proposed method outperforms other traditional methods and advanced convolutional neural network models on different datasets. Compared with convolutional neural network models such as LeNet-5, AlexNet, and ResNet, the proposed method achieves a significantly higher accuracy on the test set, with a stable accuracy of over 99%. Compared with other models, it shows better generalization and stability, effectively improving the overall performance of rolling bearing vibration signal fault diagnosis. The method provides an effective solution for the intelligent fault diagnosis of wind turbine rolling bearings.

A novel label-aware global graph construction method and spiking-coded graph neural network for intelligent process fault diagnosis

Fault diagnosis plays a crucial role in ensuring the safety and efficiency of industrial processes. However, traditional techniques often face difficulties in handling large-scale data characterized by complex structures and relationships. To efficiently represent industrial data as graphs and develop a low-energy-cost feature extraction model, a novel label-aware global graph construction method and a spiking graph convolutional network (SGCN) are proposed in this study to achieve intelligent process fault diagnosis. The label-aware method enhances graph data representation by capturing intrinsic correlations and global features. The SGCN integrates graph convolutional layers with spiking encoding, enabling effective feature extraction while offering computational efficiency advantages. A weighted loss function is introduced to mitigate data imbalance issues. Experiments on the Tennessee Eastman process, the Three-phase Flow Facility, and the de-propanizer distillation process demonstrate SGCN’s superior performance over baseline models in various fault scenarios, while significantly reducing computational costs. The proposed method offers promising potential for reliable and efficient fault diagnosis in complex real-world industrial environments.

Fault diagnosis for multiple redundancy aileron actuator based on parallel-SDP and polar sparse representation

Abstract As a critical component of aircraft flight control systems, the aileron actuator's fault directly affects the performance of flight control performance system and the overall flight safety of aircraft. Therefore, effective fault diagnosis of the aileron actuator becomes particularly important. However, with the development of redundancy design, the structure of aileron actuators more and more complex, and the fault modes are more and more diverse, which increases the difficulty of fault diagnosis significantly. To address this challenge, this study proposes a fault diagnosis method based on Parallel-SDP and Polar Sparse Representation.
First, the current residual signals of force motors are obtained using bi-step observer. Then, the residual signals are transformed into Parallel-SDP images, where each of the four petals of Parallel-SDP image generated from the corresponding channel. The Parallel-SDP image presents global fault information and capture subtle changes of residual signals, which increases the sensitivity of fault diagnosis. Subsequently, rapid single-channel fault localization is achieved by barycenter analysis of Parallel-SDP images. Finally, based on the result of fault localization, the proposed polar sparse representation algorithm is utilized for fault diagnosis of mechanical and control faults separately. Based on the dataset obtained from physical-parameter-simulation, the proposed method was validated, and the accuracy of fault diagnosis of was 99.29%, which is better than conventional fault diagnosis, meanwhile, the computational resources consumption of the proposed method is much less than deeplearning-based method, which is suitable for embedded computing system in aircraft.

In-depth research on fault diagnosis of turbine rotor utilizing NGSABO-optimized VMD and CNN-BiLSTM

Abstract To solve the problem of difficulty in extracting and identifying fault types during turbine rotor operation, a fault diagnosis method based on improved subtraction mean optimizer (NGSABO) algorithm to optimize variational mode decomposition (VMD) and CNN-BiLSTM neural network is proposed. Firstly, three improvements are made to the subtraction average optimizer algorithm. Secondly, the optimal VMD parameter combination of NGSABO adaptive selection mode decomposition number K and penalty factor is used to decompose the rotor fault signal, and the minimum sample entropy is used as the fitness function for feature extraction. Combining convolutional neural network and bidirectional long short-term memory network to identify and classify features. Compared with other methods, this method has outstanding performance in the diagnosis of single and coupled rotor faults. The accuracy of fault diagnosis reaches 98.5714%, which has good practical application value.

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.

Building Material Defect Detection and Diagnosis Method Based on Big Data and Deep Learning

Building Material Defect Detection and Diagnosis Method Based on Big Data and Deep Learning

MD-BiMamba: An aero-engine inter-shaft bearing fault diagnosis method based on Mamba with modal decomposition and bidirectional features fusion strategy

Inter-shaft bearing fault diagnosis can greatly save maintenance costs and guarantee the normal operation of aero-engines. However, existing methods are limited in their ability to handle sensor signals with high dimensional and complex noise. To tackle the above problems, we propose a Mamba network structure with Complete Ensemble Empirical Mode Decomposition with Adaptive Noise (CEEMDAN) and bidirectional feature fusion for aero-engine inter-shaft bearing fault diagnosis, called MD-BiMamba. Firstly, we utilize the CEEMDAN technique to decompose the sensor signals of inter-shaft bearings and extract the intrinsic modal function by improving the noise addition method and decomposition strategy. Then, bidirectional Mamba is designed to extract the bidirectional long-range correlation of the sequence to achieve global feature extraction and fast detection of fault types with linear complexity. Moreover, an adaptive attention fusion method is proposed to achieve bidirectional feature fusion. Finally, we use the label smoothing regularization strategy to optimize the cross-entropy loss and enhance the generalization performance. Experimental results on real inter-shaft bearing datasets and noisy datasets show that the proposed method achieves 99.88 % and 95.81 % accuracy in the standard dataset and −10 dB noise environment, respectively, which is superior to other remarkable methods, in addition to achieving lower model complexity.

Anti-forgetting source-free domain adaptation method for machine fault diagnosis

Unsupervised domain adaptation methods have made significant progress in the field of machine fault diagnosis. However, these methods generally assume the accessibility of source domain data during the cross-domain transfer phase. In practice, this assumption is often impractical due to data privacy requirements and the burden of data transmission and storage. Additionally, a key challenge lies in preventing the forgetting of source domain knowledge while performing cross-domain diagnosis in a source-free scenario. To address these issues, this paper proposes an anti-forgetting source-free domain adaptation method for machine fault diagnosis. Specifically, a prototype-based pseudo-label generation strategy, combined with a nearest-neighbor constraint, is employed to deeply explore diagnosis information in the unlabeled target domain data. Then, a fast nuclear-norm maximization constraint is introduced to reduce the density of target domain samples near the classification boundary, thereby decreasing the probability of misdiagnosis. Furthermore, a weighted Fisher regularization is designed to retain the diagnosis information of healthy states inherent in the source domain, thus mitigating information forgetting. Finally, comprehensive experiments are conducted to validate the superiority of our method in source-free cross-domain diagnosis from multiple perspectives, while also demonstrating its anti-forgetting properties.

WCNN-RSN: a novel fault diagnosis method for rolling bearing using multimodal feature fusion

Abstract Fault diagnosis of rolling bearings is significant for the safe operation of engineering equipment. Many intelligent diagnostic methods have been successfully developed. However, it is often susceptible to noisy environments. Therefore, the paper proposes a rolling bearing fault diagnosis method based on multimodal information fusion in time and time–frequency domains by combining an improved 1D-convolutional neural network (CNN) with ResNet50 wavelet improved CNN-ResNet (WCNN-RSN). The algorithm employs the Multi-Head Attention (MHA) mechanism to complementarily fuse fault features in different scales, achieving fault diagnosis by fully extracting fault features. The experimental results show that the diagnostic effect of WCNN-RSN is better than that of the comparison methods under noise interference, which proves that the proposed method possesses good anti-noise and generalization ability.

Label-guided contrastive learning with weighted pseudo-labeling: A novel mechanical fault diagnosis method with insufficient annotated data

Exploring fault diagnosis methods for mechanical equipment with weak dependency on annotated data is essential for industrial production. Contrastive learning (CL), capable of learning representations without labeling information, has achieved satisfactory performance in mechanical fault diagnosis. However, current CL-based approaches mainly encounter two limitations. First, the pre-training stage uses either unannotated or annotated samples exclusively while the fine-tuning stage solely relies on annotated ones, leading to inefficient sample utilization. Second, the representation learned by contrastive loss alone in the pretext task is sub-optimal for downstream diagnostic tasks. To address these issues, this paper proposed a novel diagnostic framework based on label-guided contrastive learning (LgCL) and weighted pseudo-labeling (WPL) strategy to improve fault diagnosis accuracy. In the pre-training stage, the proposed LgCL integrates two types of contrastive loss together with classification loss, enabling the encoder to learn discriminative representations that directly benefit the downstream diagnostic task. The devised hybrid fine-tuning strategy allows both labeled and unlabeled data to participate in fine-tuning via pseudo-labeling, enhancing model generalization. The pertinently designed WPL strategy mitigates the defect of noisy pseudo labels. Comparison and ablation experiments on two public datasets and one self-designed dataset validate the superiority of the proposed method for fault diagnosis with limited annotated data, with diagnostic accuracies improved by 25.30%, 5.47% and 10.02% over supervised, semi-supervised and contrastive learning methods, respectively.

Network Data Intrusion Detection and Data Feature Extraction of Electromechanical Facilities from Machine Learning

With the rapid development of Internet technology, network security issues have become more complex and changeable. Various intrusion methods threaten the information network environment in the Electromechanical Facility (EF) system. This paper focuses on EF to study the relevant detection methods and data feature extraction in complex network intrusions. Firstly, four common machine learning algorithms are used to calculate the data set. The advantages and disadvantages of each algorithm are analyzed after tuning and comparison. Secondly, a network intrusion detection algorithm is proposed based on Recursive Feature Elimination (RFE) principal component analysis. It uses RFE to reduce the number of features and improve the elimination judgment index to align with the detection requirements of information network datasets. Finally, a fault diagnosis method is proposed based on empirical pattern decomposition and support vector machine under Renyi entropy complexity measurement. This method trains and identifies the Renyi entropy of several basic pattern components obtained by decomposing empirical patterns as feature vectors. The results show that the RFE method judged by random forest removes irrelevant features, and the evaluation index is improved to align with the network dataset’s detection requirements. It reduces the data dimension, reduces the operation time, and improves the accuracy of a few attack types. The comprehensive final detection effect is better than other algorithms. Additionally, the embedded operating system construction method based on the protection mechanism realizes the separate storage of the operating system and key data. Also, it can prevent the network system from being maliciously invaded, ensuring the stability of the instrument operation under harsh working conditions.

A Mechanical Fault Diagnosis Method for UCG-Type On-Load Tap Changers in Converter Transformers Based on Multi-Feature Fusion

The On-Load Tap Changer (OLTC) is the only movable mechanical component in a converter transformer. To ensure the reliable operation of the OLTC and to promptly detect mechanical faults in OLTCs to prevent them from developing into electrical faults, this paper proposes a fault diagnosis method for OLTCs based on a combination of Particle Swarm Optimization (PSO) algorithm and Least Squares Support Vector Machine (LSSVM) with multi-feature fusion. Firstly, a multi-feature extraction method based on time/frequency domain statistics, synchrosqueezed wavelet transform, singular value decomposition, and multi-scale modal decomposition is proposed. Meanwhile, the random forest algorithm is used to screen features to eliminate the influence of redundant features on the accuracy of fault diagnosis. Secondly, the PSO algorithm is introduced to optimize the hyperparameters of LSSVM to obtain optimal parameters, thereby constructing an optimal LSSVM fault diagnosis model. Finally, different types of feature combinations are utilized for fault diagnosis, and the impact of these feature combinations on the fault diagnosis results is compared. Experimental results indicate that features of different types can complement each other, making the OLTC state information carried by multi-dimensional features more comprehensive, which helps to improve the accuracy of fault diagnosis. Compared with four traditional fault diagnosis methods, the proposed method performs better in fault diagnosis accuracy, achieving the highest accuracy of 98.58%, which can help to detect mechanical faults in the OLTC early and reduce the system’s downtime.

Few-shot bearing fault diagnosis method based on an EEMD parallel neural network and a relation network

Bearing fault diagnosis presents challenges, such as insufficient fault samples and significant fault data distribution variation in different bearing operating conditions. These problems cause traditional deep learning models to show poor generality and accuracy during bearing fault diagnosis. To address these challenges, this paper proposed a few-shot bearing fault diagnosis method based on an Ensemble Empirical Mode Decomposition (EEMD) parallel neural network and a relation network (RN). First, the original bearing fault vibration signal was decomposed by EEMD, while the decomposed signal components were processed via Short Time Fourier Transfor (STFT) to obtain a two-dimensional time-frequency feature map. Then, a parallel neural network was used for initial fault feature extraction, after which the extracted features were fused to construct a more accurate multi-dimensional fault feature map. A more precise fault feature vector was generated via the feature embedding module of the RN, and the fault features of the support and query sets were stitched to create a fault feature vector set. Finally, the relation module of the RN was used for the nonlinear distance determination of the fault feature vector set and to generate the relation score for the few-shot variable condition bearing fault diagnosis. In this paper, EEMD module is introduced into RN to construct multi-dimensional fault characteristics of the original fault signal. Original signal decomposition, STFT transformation and splicing effectively improve the randomness and blindness of convolution operations, improve the accuracy of fault feature extraction in RN, and thus improve the overall diagnostic performance of the model. The experimental results showed that the proposed model obtained higher diagnostic accuracy than the matching network (MN) and RN meta-learning fault diagnosis (MLFD) methods. The accuracy of fault diagnosis of the model in 5Way-Nshot is >80%, and the accuracy of fault diagnosis in 5Way-10shot is the highest at 95.2%.

Improved center loss-based metric learning for fault diagnosis of water injection pump

Abstract As the key machine for oil extraction, the water injection pump plays an essential role in ensuring the safe and stable production of oil. However, the water injection pump is prone to failures during operation, leading to considerable losses due to frequent shutdowns. Therefore, it is of great significance to develop an intelligent fault diagnosis method. In this work, a fault diagnosis method with improved center loss-based metric learning is proposed. Firstly, a multi-scale convolution with an attention mechanism is employed to extract key fault features from different temporal-spatial scales with adaptive weighted fusion. Furthermore, an improved center loss is imposed as a constraint on the network-generated embedding space, which enables better clustering of embedding features and consequently a reliable decision boundary for different health states. The proposed method is validated on water injection pump data and outperforms multiple comparative methods, which is able to maintain a better performance even in a highly noisy operating environment.

A Novel Fault Feature Selection and Diagnosis Method for Rotating Machinery with SI-IR2CMSE and SSGMM-SR

Abstract In the field of fault diagnosis, machine learning is highly valued for its broad applicability and efficiency. Feature extraction and feature selection are key steps in the application of machine learning, and the performance of fault diagnosis methods relies heavily on the effective execution of these two steps. For this reason, this paper aims to enhance the performance of fault diagnosis methods by improving these two aspects. Firstly, to address the non-linearity and non-stationarity of rotating machinery vibration signals under variable operation conditions, this paper proposes an improved rapid refined composite multiscale sample entropy (IR2CMSE) feature extraction method. In addition, this paper decomposes the vibration signals with improved complete ensemble empirical mode decomposition with adaptive noise (ICEEMDAN) and extracts the sensitive intrinsic modal functions’ (IMFs') IR2CMSE values (SI-IR2CMSE) as the initial feature vector, which more accurately reveals the intrinsic time-scale characteristics of the vibration signals. Secondly, to address the problem of over-reliance on sample labels in most feature selection methods, this paper proposes a semi-supervised Gaussian mixing model with sparse regularization (SSGMM-SR) feature selection model. The model does not require complete fault labels and can automatically identify important features. Finally, validation with two rotating machinery fault datasets shows that the method proposed in this study exhibits high diagnostic accuracy and stability across multiple classifiers.

Envelope spectrum neural network with adaptive domain weight harmonization for intelligent bearing fault diagnosis under cross-machine scenarios

Accurate bearing fault diagnosis technology is highly important for ensuring the safe operation of mechanical equipment. Fault diagnosis methods can be roughly divided into signal processing-based methods (SPM) and data-driven methods (DDMs), which rely on physical knowledge and data knowledge, respectively. However, SPM cannot adapt to large data samples and dynamic parameter variations. DDMs did not consider physical representation consistency. To address the above issues, an envelope spectrum neural network (ESNN) is proposed for cross-machine bearing fault diagnosis. First, a deep transfer convolution network (DTCN) is constructed as the basic diagnostic framework. Second, a knowledge-to-model conversion strategy (KMC) is built to create ESNN, which utilizes equivalent convolution functions to construct the first two layers of DTCN, guiding the model to learn physical knowledge. Subsequently, an adaptive domain weight harmonization (ADWH) mechanism is proposed that can dynamically combine marginal distributions and joint distributions and automatically learn hidden features contained in physical and data knowledge, thus alleviating domain shift issues. Experimental evaluations are conducted using fault datasets from three different machines. The results show that, compared to models without knowledge guidance, ESNN achieves a 6.4% improvement in diagnostic accuracy. Compared to many advanced models, ESNN can achieve a maximum diagnostic accuracy improvement of 35.94%. The code of the ESNN can be found at https://github.com/John-520/ESNN.

A Semantic Alignment Guided Transfer-Learning Method for Electro-Mechanical Actuator Fault Diagnosis Under Variable Working Conditions

A Semantic Alignment Guided Transfer-Learning Method for Electro-Mechanical Actuator Fault Diagnosis Under Variable Working Conditions

Domain adaptation between heterogeneous time series data: A case study on real-time rotary machinery fault diagnosis

Artificial intelligence (AI) in fault diagnosis has emerged as a significant tool for addressing anomalies in rotary machineries (RMs). However, the success of AI models in this context largely depends on situations where the distribution of samples in the training dataset closely aligns with that of the testing dataset. In addition, practically, it is very difficult, costly, or even impossible to collect sufficient time series samples with proper labeling for AI modeling. To address these issues, this paper presents a study developing a structured methodology called frequency-domain supervised domain adaptation (FDSDA) considering heterogeneous data from versatile sensor technologies. In the context of application, two high-dimensional datasets were generated, each following distinct distributions: one being the vibration signals and the other the acoustic signals. The modeling begins with transforming signals from the time domain to the frequency domain through frequency analysis. Subsequently, a domain adaptation model is implemented, adopting an ensemble learning as an estimator to address the covariate shift challenge. Two experiments are conducted with the proposed method for binary and multi-class fault diagnosis of RMs. The results demonstrate that, despite having limited training and target data, the proposed method can effectively detect RMs fault conditions by outperforming the benchmark method.

Neural architecture search for multi-sensor information fusion-based intelligent fault diagnosis

The multi-sensor information fusion-based intelligent fault diagnosis (MIF-IFD) method using deep learning aims to provide more accurate and reliable ways of identifying equipment health status than single-sensor methods. However, designing feature extraction modules in deep networks and determining information fusion execution layers still requires expertise and extensive experimentation, imposing high development costs. This limitation impedes the development and application of MIF-IFD. This paper proposes an architecture to mitigate the development challenges of MIF-IFD. Firstly, the basic module of the network consists of searchable feature extraction cells and a mask self-attention mechanism to achieve the extraction and fusion of multi-sensor information. Secondly, the optimal feature extraction cells and fusion starting layers are searched by constructing a continuous search space to compose the optimal fusion diagnostic structure, respectively. Finally, validation and analysis are conducted using two experimental datasets. The results demonstrate that the proposed method not only ensures diagnostic accuracy but also significantly improves development efficiency.

Knowledge-informed FIR-based cross-category filtering framework for interpretable machinery fault diagnosis under small samples

Relying on sufficient training data, the existing fault diagnosis methods rarely focus on the methodological interpretability and the data scarcity in real industrial scenarios simultaneously. Motivated by this issue, we deeply reexamined the intrinsic characteristics of fault signals and the guiding significance of classical signal-processing methods for feature enhancement. From the perspective of multiscale modes, this study tailors multiple learnable knowledge-informed finite impulse response (FIR) filtering kernels to extract sensitive modes for explainable feature enhancement. On this foundation, a knowledge-informed FIR-based cross-category filtering (FIR-CCF) framework is further proposed for interpretable small-sample fault diagnosis. With the consideration of the mode complexity, a cross-category filtering strategy is explored to further enhance feature expressions for identifying single state. To be special, this strategy divides a multi-class recognition process into multiple two-class recognition task. A multi-task learning is then presented where multiple binary-class base learners (BCBLearners) that consists of a feature extractor and a two-class classifier is established to seek discriminate mode features for each type of state. Eventually, all feature extractors are fixed and a multi-class classifier is established and to fuse all mode features for high-precision multi-class identification via ensemble learning. As a variant of signal-processing-collaborated deep learning frameworks, the FIR-CCF method fully exploits the strengths of signal-processing methods in interpretability and feature extraction. Three experimental cases highlight the superiority and significant improvement of the FIR-CCF framework over other five state-of-the-art diagnosis methods and three ablation models. Specially, extensive visualization is implemented to place in-depth insight into how the FIR-CCF framework works. It can be also foreseen that the signal-processing-collaborated deep learning framework shows enormous potential in interpretable fault diagnosis for knowledge-informed artificial intelligence. Related source codes will be available at: https://github.com/BITS/FIR-CCF-main.