Fault Samples Research Articles

SCCAM: Supervised Contrastive Convolutional Attention Mechanism for Ante-Hoc Interpretable Fault Diagnosis With Limited Fault Samples.

In real industrial processes, fault diagnosis methods are required to learn from limited fault samples since the procedures are mainly under normal conditions and the faults rarely occur. Although attention mechanisms have become increasingly popular for the task of fault diagnosis, the existing attention-based methods are still unsatisfying for the above practical applications. First, pure attention-based architectures like transformers need a substantial quantity of fault samples to offset the lack of inductive biases thus performing poorly under limited fault samples. Moreover, the poor fault classification dilemma further leads to the failure of the existing attention-based methods to identify the root causes. To develop a solution to the aforementioned problems, we innovatively propose a supervised contrastive convolutional attention mechanism (SCCAM) with ante-hoc interpretability, which solves the root cause analysis problem under limited fault samples for the first time. First, accurate classification results are obtained under limited fault samples. More specifically, we integrate the convolutional neural network (CNN) with attention mechanisms to provide strong intrinsic inductive biases of locality and spatial invariance, thereby strengthening the representational power under limited fault samples. In addition, we ulteriorly enhance the classification capability of the SCCAM method under limited fault samples by employing the supervised contrastive learning (SCL) loss. Second, a novel ante-hoc interpretable attention-based architecture is designed to directly obtain the root causes without expert knowledge. The convolutional block attention module (CBAM) is utilized to directly provide feature contributions behind each prediction thus achieving feature-level explanations. The proposed SCCAM method is testified on a continuous stirred tank heater (CSTH) and the Tennessee Eastman (TE) industrial process benchmark. Three common fault diagnosis scenarios are covered, including a balanced scenario for additional verification and two scenarios with limited fault samples (i.e., imbalanced scenario and long-tail scenario). The effectiveness of the presented SCCAM method is evidenced by the comprehensive results that show our method outperforms the state-of-the-art methods in terms of fault classification and root cause analysis.

Transformer fault diagnosis based on adversarial generative networks and deep stacked autoencoder

Establishing a deep learning model for transformer fault diagnosis using transformer oil chromatogram data requires a large number of fault samples. The lack and imbalance of oil chromatogram data can lead to overfitting, lack of representativeness of the model, and unsatisfactory prediction results on test set data, making it difficult to accurately diagnose transformer faults. A conditional Wasserstein generative adversarial network with gradient penalty optimization (CWGAN-GP) is adopted in this paper, which based on gradient penalty optimization and expand the oil chromatography fault samples of 500 sets of transformer oil chromatography data with 5 types of faults. The proposed method is used to classify transformer faults using a deep autoencoder, and the sample quality of the neural network model proposed in this paper is compared with several other variants of generative adversarial neural network models. The research results show that after using the method proposed in this paper for sample expansion, the overall accuracy of fault diagnosis can reach 93.2 %, which is 4.98 % higher than the original imbalanced samples. Compared with other sample expansion methods, the accuracy of fault diagnosis of the algorithm in this paper is improved by 1.70 %–3.05 %.

Rolling bearing fault diagnosis based on multi-source data fusion

In this paper, a fault diagnosis method is proposed based on multi-source data fusion to address the inaccurate results caused by single evidence used for decision-making. First, empirical mode decomposition is performed using sensor data to extract fault features, and a fault feature matrix and a diagnostic matrix are established. Then the deviation vector is defined to obtain the difference between the diagnostic sample and the fault sample, and then the basic probability assignment is obtained for each diagnostic sample. Finally, the Dempster combination rule is used for fusion. The effectiveness and accuracy of this method in fault diagnosis of rolling bearings have been verified through examples of rolling bearings.

An Integrated Multitasking Intelligent Bearing Fault Diagnosis Scheme Based on Representation Learning Under Imbalanced Sample Condition.

Accurate bearing fault diagnosis is of great significance of the safety and reliability of rotary mechanical system. In practice, the sample proportion between faulty data and healthy data in rotating mechanical system is imbalanced. Furthermore, there are commonalities between the bearing fault detection, classification, and identification tasks. Based on these observations, this article proposes a novel integrated multitasking intelligent bearing fault diagnosis scheme with the aid of representation learning under imbalanced sample condition, which realizes bearing fault detection, classification, and unknown fault identification. Specifically, in the unsupervised condition, a bearing fault detection approach based on modified denoising autoencoder (DAE) with self-attention mechanism for bottleneck layer (MDAE-SAMB) is proposed in the integrated scheme, which only uses the healthy data for training. The self-attention mechanism is introduced into the neurons in the bottleneck layer, which can assign different weights to the neurons in the bottleneck layer. Moreover, the transfer learning based on representation learning is proposed for few-shot fault classification. Only a few fault samples are used for offline training, and high-accuracy online bearing fault classification is achieved. Finally, according to the known fault data, the unknown bearing faults can be effectively identified. A bearing dataset generated by rotor dynamics experiment rig (RDER) and a public bearing dataset demonstrates the applicability of the proposed integrated fault diagnosis scheme.

Self-Supervised Simple Siamese Framework for Fault Diagnosis of Rotating Machinery With Unlabeled Samples.

Fault diagnosis is vital to ensuring the security of rotating machinery operations. While fault data obtained from mechanical equipment for this issue are often insufficient and of no labels. In this case, supervised algorithms cannot come into play. Hence, this article proposes a self-supervised simple Siamese framework (SSF) for bearing fault diagnosis based on the contrastive learning algorithm SimSiam which uses a simplified Siamese network to find the distinguishable features of different fault categories. SSF consists of a weight-sharing encoder applied on two inputs, a nonlinear predictor and a linear classifier. SSF learns invariant characteristics of fault samples via maximizing the similarity between two views of each inputted sample. Several data augmentation (DA) methods for vibration signals, which provide different sample views for the model, are also studied, for it is crucial for contrastive learning. After fine-tuning the learned encoder and a linear layer classifier with a small subset of labeled data (1%-5% of the total samples), the network achieves satisfactory performance for bearing fault diagnosis. A series of experiments based on the data from three different scenarios are used to verify the proposed methods, getting 100%, 99.38%, and 98.87% accuracy separately.

Chemical fault diagnosis network based on single domain generalization

Recent developments in fault diagnosis have leveraged domain generalization to address the issue of domain shift. Most existing methods focus on learning domain-invariant representations from multiple source domains. However, collecting valuable fault samples from varying operational conditions is challenging, and it is common for available data to originate from a single operational condition. Thus, this paper introduces a Multi-scale generative and adversarial Metric networks (MGAMN) for Chemical Process Fault Diagnosis. To enhance model generalization, a domain generation module was developed to create augmented domains with significant distributional differences from the source domain. The diagnostic task module then extracts domain-invariant features from both the source and augmented domains. A multi-scale generation strategy is established, utilizing multi-scale deep separable convolutions (Dsc) to ensure that the generated samples contain rich state information. Additionally, an adversarial training and metric learning strategy is designed to learn generalized features capable of resisting unknown domain shifts. Extensive diagnostic experiments on the non-isothermal continuous stirred tank reactor (CSTR) and the Tennessee Eastman Process (TEP) chemical datasets validate the effectiveness of the proposed method. Moreover, ablation studies confirm the effectiveness of the proposed modular strategy, demonstrating significant potential for practical applications.

CBAM-CRLSGAN: A novel fault diagnosis method for planetary transmission systems under small samples scenarios

In various and complex industrial scenarios, the fault data acquisition of planetary transmission system is expensive and unavailable, thus intelligent fault diagnosis under small fault samples scenarios is a challenging task. Therefore, we propose a Convolutional Block Attention Mechanism Conditional Regularized Least Squares Generative Adversarial Network (CBAM-CRLSGAN) method for intelligent diagnosis of planetary transmission systems. First, the diversity of original samples is increased by an overlapping segmentation strategy. Then, a novel data augmentation method is proposed via incorporating the CBAM module and conditional regularized least squares loss function into least squares generative adversarial network, which enables the proposed method to extract data features efficiently and improve training stability. Finally, the real and obtained fake samples are input into the classifier to realize fault diagnosis. The experimental results on the planetary transmission system test rig show that the proposed CBAM-CRLSGAN can obtain superior diagnostic performance with a diagnosis accuracy of 99.35%.

Fault Diagnosis Based on Tensor Computing and Meta-Learning for Smart Grid and Power Communication Network

Fault diagnosis (FD) is a critical challenge for the smart grid and the power communication network, especially when both heterogeneous networks are exponentially becoming enormous and complicated. Consequently, some conventional FD schemes based on labor seem inefficient, even disabled, because they usually cannot efficiently utilize multi-dimensional and heterogeneous big data from both networks. To deal with this challenging technical problem, a novel FD scheme based on tensor computing and meta-learning is proposed for the smart grid and the power communication network. In the proposed scheme, tensor computing is used to process tensor big data from both networks, and a new data fusion scheme is designed to complete and analyze the incomplete and sparse big data. Based on the fused data, a meta-learning approach is used to construct the FD scheme, especially when the target fault samples are inadequate and sparse. In meta-learning, the convolutional neural network is employed as a base learner to generate an FD training model, and the model-agnostic meta-learning algorithm is utilized to fine-tune and further train the pre-trained model. Simulation results and theoretical analysis indicate that the proposed DF scheme based on tensor computing can efficiently process sparse and heterogeneous big data from both networks. Furthermore, the meta-learning-based FD scheme provides an efficient way to diagnose faults with inadequate target samples. The proposed FD scheme based on tensor computing and meta-learning provides a novel solution to detect and analyze the potential faults for smart grid and power communication networks.

An imbalance multi-faults data transfer learning diagnosis method based on finite element simulation optimization model of rolling bearing

In practical engineering applications, rotating machinery is often in a healthy state, with more healthy samples and fewer multi-faults samples, which leads to be misdiagnosed. A finite element simulation model (FEM) is proposed to expand imbalanced multi-faults sample data. However, there is a significant difference in vibration response between the FEM simulation data and the measured data collected on the rotating machinery. Therefore, a method based on vibration response eigenvalue model correction has been adopted, aiming to narrow the gap between the simulation data and the measured data. In order to solve the problem of low accuracy of sample imbalance fault diagnosis under different working conditions, a transfer learning (TL) fault diagnosis method based on finite element simulation optimization model of rolling bearings to supplement imbalanced multi-fault data is proposed. Firstly, the FEM of healthy bearings is established, and the optimal radial clearance of bearings is obtained by modifying the vibration response eigenvalue model. Then, corresponding simulated fault vibration responses were obtained by setting composite faults on the optimal model. Finally, supplementing the unbalanced fault data with simulation data to create a mixed balanced dataset as samples, the TL model is trained to accomplish intelligent fault diagnosis for multi-faults. The experimental results show that using mixed data as training samples to train neural network models can improve the accuracy of transfer learning fault diagnosis by over 10%. Expanding fault samples by modifying the bearing clearance of the FEM is an effective method to address sample imbalance.

Image Enhancement Based on Dual-Branch Generative Adversarial Network Combining Spatial and Frequency Domain Information for Imbalanced Fault Diagnosis of Rolling Bearing

To address the problems of existing 2D image-based imbalanced fault diagnosis methods for rolling bearings, which generate images with inadequate texture details and color degradation, this paper proposes a novel image enhancement model based on a dual-branch generative adversarial network (GAN) combining spatial and frequency domain information for an imbalanced fault diagnosis of rolling bearing. Firstly, the original vibration signals are converted into 2D time–frequency (TF) images by a continuous wavelet transform, and a dual-branch GAN model with a symmetric structure is constructed. One branch utilizes an auxiliary classification GAN (ACGAN) to process the spatial information of the TF images, while the other employs a GAN with a frequency generator and a frequency discriminator to handle the frequency information of the input images after a fast Fourier transform. Then, a shuffle attention (SA) module based on an attention mechanism is integrated into the proposed model to improve the network’s expression ability and reduce the computational burden. Simultaneously, mean square error (MSE) is integrated into the loss functions of both generators to enhance the consistency of frequency information for the generated images. Additionally, a Wasserstein distance and gradient penalty are also incorporated into the losses of the two discriminators to prevent gradient vanishing and mode collapse. Under the supervision of the frequency WGAN-GP branch, an ACWGAN-GP can generate high-quality fault samples to balance the dataset. Finally, the balanced dataset is utilized to train the auxiliary classifier to achieve fault diagnosis. The effectiveness of the proposed method is validated by two rolling bearing datasets. When the imbalanced ratios of the four datasets are 0.5, 0.2, 0.1, and 0.05, respectively, their average classification accuracy reaches 99.35% on the CWRU bearing dataset. Meanwhile, the average classification accuracy reaches 96.62% on the MFS bearing dataset.

Open-circuit fault diagnosis method of inverter in wind turbine yaw system based on GADF image coding

Considering the concealment of inverter open-circuit faults in yaw system of wind turbines, a method for diagnosing open-circuit fault of yaw system inverter is proposed based on Gramian Angular Difference Field (GADF) image coding in this article. Firstly, the current vector phase in the vicinity of relatively high yaw speed is collected as monitoring data. Secondly, considering the insufficient fault feature extraction ability of Convolutional Neural Network (CNN) structures with single dimensional data input during model training, the one-dimensional current vector phase is encoded into two-dimensional image by GADF image coding and an effective CNN fault diagnosis model is obtained with fewer fault samples. Finally, by comparing with actual monitoring data of wind turbine, the effectiveness of yaw system simulation model is verified. The proposed method can achieve identification and localization of open-circuit fault for single and two power devices, which is found to have better anti-noise interference effect and the results are not affected by yaw angle and mechanical torque. It is approved that the proposed method is effective with a simulation on the RT-LAB platform.

Application of time‐space neighborhood standardization technology to complex multi‐stage process fault detection

AbstractTo solve the problem that the multi‐stage process with dynamicity and nonlinear is hard to monitor effectively, the time‐space neighborhood standardization (TSNS) method is proposed, which is further applied to partial least squares (PLS) to propose TSNS and PLS (TSNS‐PLS) method for process fault detection. TSNS can transform multi‐stage data into single‐stage data that approximately obeys a standard normal distribution, remove temporal correlation between samples at previous and subsequent moments in the process data, and separate online fault samples. TSNS makes the transformed process data satisfy the requirements of the PLS method for process data and can significantly improve the fault detection rate of the PLS method. Finally, the performance of TSNS‐PLS was examined by a numerical simulation process and the penicillin fermentation process design fault detection experiment.

SSFLNet: A Novel Fault Diagnosis Method for Double Shield TBM Tool System.

In tunnel boring projects, wear and tear in the tooling system can have significant consequences, such as decreased boring efficiency, heightened maintenance costs, and potential safety hazards. In this paper, a fault diagnosis method for TBM tooling systems based on SAV-SVDD failure location (SSFL) is proposed. The aim of this method is to detect faults caused by disk cutter wear during the boring process, which diminishes the boring efficiency and is challenging to detect during construction. This paper uses SolidWorks to create a complete three-dimensional model of the TBM hydraulic thrust system and tool system. Then, dynamic simulations are performed with Adams. This helps us understand how the load on the propulsion hydraulic cylinder changes as the TBM tunneling tool wears to different degrees during construction. The hydraulic propulsion system was modeled and simulated using AMESIM software. Utilizing the load on the hydraulic propulsion cylinder as an input signal, pressure signals from the two chambers of the hydraulic cylinder and the system's flow signal were acquired. This enabled an in-depth exploration of the correlation between these acquired signals and the extent of the tooling system failure. Following this analysis, a collection of normal sample data and sample data representing different degrees of disk cutter abrasions was amassed for further study. Next, an SSFL network model for locating the failure area of the cutter was established. Fault sample data were used as the input, and the accuracy of the fault diagnosis model was tested. The test results show that the performance of the SSFL network model is better than that of the SAE-SVM and SVDD network models. The SSFL model achieves 90% accuracy in determining the failure area of the cutter head. The model effectively identifies the failure regions, enabling timely tool replacement to avoid decreased boring efficiency under wear conditions. The experimental findings validate the feasibility of this approach.

Domain graph attention neural network: A new mechanical fault diagnosis method with few samples

Mechanical fault diagnosis is currently a highly trending topic, facing two significant challenges. Firstly, the acquisition of an ample number of fault samples proves to be difficult, thereby limiting access to sufficient data samples. Secondly, intricate and non-mathematically describable associations often exist among different faults. Most algorithms treat fault samples as isolated entities, consequently impacting the accuracy of fault diagnosis. This paper proposes a novel machine learning framework called Domain Graph Attention Neural Network (DGAT), which leverages the topological structure of graphs to effectively capture the interrelationships among fault samples. Additionally, this framework incorporates domain information during node updates to obtain richer embeddings, particularly in scenarios with limited available samples. It effectively overcomes the fixed receptive field limitation of the original Graph Attention Network (GAT). In order to validate the effectiveness of the model, we conducted extensive comparative experiments on diverse datasets, which demonstrated the superior performance of the proposed model.

ALTASN: A few-shot learning fault diagnosis method for rotating machinery of unmanned surface vehicles based on attention mechanism

Rotating machinery is one of the principal power equipment of unmanned surface vehicles (UVs). Considering the complex and harsh offshore working conditions of UVs, the health status of rotating machinery is highly to be affected, but it is often difficult to obtain enough fault samples. Accordingly, limited data fault diagnosis of rotating machinery holds great practical significance to increase the resilience and security of UVs. For limited data fault diagnosis, a novel few-shot learning model based on attention mechanism called adaptive long-term attention siamese network (ALTASN) is proposed. First, an efficient channel attention mechanism is combined with adaptive convolutional kernels to improve the spatial feature extraction capabilities of the convolutional neural network (CNN). To capture and assign higher weights to important long-term dependent information, long-term attention is introduced to improve the ability of long short-term memory networks (LSTM) temporal feature extraction. Finally, the siamese network is introduced to compare the features of different sample pairs to obtain the final fault type. In the case of limited data, the fault diagnosis performance and generalization ability of the proposed ALTASN are better compared with existing results. Experiments are carried out on the actual three-phase asynchronous motor experiment platform at the Zhejiang University of Technology to verify the effectiveness and generalization of the proposed method.

Intelligent fault diagnosis of rolling bearings under small samples based on lightweight UNet with attention-fused residual block

In rotating machinery, rolling bearings are crucial, and their failure can lead to severe accidents and economic losses. Therefore, fault diagnosis of bearings is necessary to maintain the safe and stable operation of modern machinery and equipment. Currently, data-driven intelligent diagnosis methods are mainstream; however, in practical applications, problems such as insufficient fault samples and strong interference signals often exist. At the same time, a large number of edge-end and mobile devices put higher requirements for the size of the diagnostic model. This study addresses these issues by proposing a lightweight UNet (LWUNet) model, which integrates wavelet packet decomposition (WPD) and attention-fused residual block (AFRB) for fault diagnosis in rolling bearings under varying operating conditions, particularly for small sample sizes. Firstly, WPD is used to decompose and reconstruct the fault signal to achieve effective denoising. Secondly, a LW-UNet is constructed for pixel-level feature learning to reduce the number of parameters and improve the accuracy rate. Thereafter, to further enhance the model feature extraction capability, the AFRB is proposed and embedded into the LWUNet to develop the AFRB-LWUNet model. Finally, the reconstructed signals are input to the proposed model for training, and the model performance is examined using a test set. The proposed method is compared with other fault diagnosis models using small sample data of rolling bearings from the Case Western Reserve University, USA and the University of Paderborn, Germany. The results confirm the higher recognition accuracy, stronger generalization ability, and robustness of the proposed method for small samples under various working conditions and intense noise.

Fault Diagnosis Method of Box-Type Substation Based on Improved Conditional Tabular Generative Adversarial Network and AlexNet

To solve the problem of low diagnostic accuracy caused by the scarcity of fault samples and class imbalance in the fault diagnosis task of box-type substations, a fault diagnosis method based on self-attention improvement of conditional tabular generative adversarial network (CTGAN) and AlexNet was proposed. The self-attention mechanism is introduced into the generator of CTGAN to maintain the correlation between the indicators of the input data, and a large amounts of high-quality data are generated according to the small number of fault samples. The generated data are input into the AlexNet model for fault diagnosis. The experimental results demonstrate that compared with the SMOTE and CTGAN methods, the dataset generated by the self-attention-conditional tabular generative adversarial network (SA-CTGAN) model has better data relevance. The accuracy of fault diagnosis by the proposed method reaches 94.81%, which is improved by about 11% compared with the model trained on the original data.

Interpretable multi-domain meta-transfer learning for few-shot fault diagnosis of rolling bearing under variable working conditions

To address the challenges of accurately diagnosing few-shot fault samples obtained from rolling bearings under variable operating conditions, as well as the issues of black box nature and delayed feedback to guide fault handling in intelligent diagnostic models, this paper proposes an interpretable multi-domain meta-transfer learning method. Firstly, vibration monitoring data of rolling bearings under different operating conditions are collected, and time–frequency domain features are extracted to construct multi-channel one-dimensional temporal samples as inputs. A multi-domain meta-transfer learning framework based on deep convolutional neural networks is then built to perform few-shot learning with multiple tasks under different operating conditions. The output results are reverse-reconstructed through a fusion hierarchical class activation mapping, and the feature maps are assigned different weights to obtain saliency maps corresponding to the inputs, thus improving the interpretability of the output results. Finally, the dataset of bearing vibration data under time-varying rotational speed conditions is used to validate the effectiveness of the proposed method. Experimental results show that the proposed method can achieve accurate fault diagnosis results under variable operating conditions with few-shot samples, and the diagnosis results can be fed back to the input for decision-making, enhancing the interpretability of the model. Compared with other models, it also demonstrates better robustness and accuracy.

Few-shot fault diagnosis of turnout switch machine based on flexible semi-supervised meta-learning network

The safety of train operations hinges on the reliability of the signal system, and the switch machine stands out as a pivotal component within it. Consequently, fault diagnosis of switch machines is of paramount importance. However, obtaining a substantial amount of fault data is challenging in reality, and labeled data is even scarcer, which makes the fault diagnosis model of the switch machine have low diagnostic accuracy and poor generalization ability. To address these problems, a flexible semi-supervised meta-learning network (FSMN) is proposed for the fault diagnosis of switch machines in this paper. Firstly, a dual-channel hetero-convolution kernel feature extractor (DHKFE) is efficiently proposed to extract the switch machine fault features at different levels from few-shot samples. Secondly, a flexible distance prototype corrector is employed to adaptively modify the distance function. It accomplishes this by rapidly identifying similarities among fault samples and harnessing the potential of unlabeled data to fine-tune prototype positions, which can enhance prototype stability and generalization, leading to more accurate fault classification. Finally, the A-phase current data collected in the real scene during the transition between the two states of the switch machine are utilized for the validation of FSMN, alongside a comparative assessment against five other methods. The results show that the accuracy in forward-reverse and reverse-forward of FSMN is up to 97.35% and 92.72%, respectively, which means FSMN is superior in few-shot fault diagnosis and can be applied to various switch machines.

Model-Assisted Muti-source Fusion Hypergraph Convolutional Neural Networks for intelligent few-shot fault diagnosis to Electro-Hydrostatic Actuator

Electro-Hydrostatic Actuator (EHA) is a critical electro-hydraulic actuator system widely used in aerospace equipment. To ensure its normal operation, the intelligent fault diagnosis of the EHA system has gained increasing attention. However, the EHA exhibits strong nonlinearity, high structural complexity, and difficulty obtaining fault samples. A Model-Assisted Multi-source Fusion Hypergraph Convolutional Neural Network (MAMF-HGCN) is proposed to address the few-shot intelligent fault diagnosis of EHA. Specifically, the fault data obtained from the hydraulic simulation model is used to establish the relationship among each channel signal. This assists in constructing a hypergraph structure for actual multi-source fault data under limited samples. Each node in the hypergraph employs message transmission to fuse signals from different channels. Subsequently, the hypergraph data are input into the constructed hypergraph convolutional neural network to perform fault classification. Finally, validating the EHA hydraulic system test rig from Nanjing University of Science and Technology illustrates the method’s effectiveness in diagnosing hydraulic system problems under limited fault samples.