Types Of Bearing Faults Research Articles

The intelligent operation and maintenance method and experimental research of CNC machine tool bearings

As the core components of high-precision rotary machine tools, machine tool bearings are prone to failure or damage, and their running state directly affects the safety and reliability of the entire equipment. Therefore, the paper proposes an intelligent operation and health management method for machine tool bearings based on Bayes-VMD-KPCA, Bayes-CNN-SVM, and health status evaluation index. Aiming at the complex working environment and high nonlinear degree of fault features of machine tool bearings, the Bayes-VMD-KPCA algorithm is used to perform variational mode decomposition of the original signal of the bearing fault, which avoids the influence of background noise and solves the problem of high dimension of multi-domain fault feature set. Second, the CNN-SVM fault diagnosis model uses a convolutional neural network (CNN) to deeply mine the extracted multi-domain fault features, and a support vector machine (SVM) can be used as a fault classifier to complete the diagnosis of various fault types of machine tool bearings. At the same time, the Bayes algorithm is introduced to tune the hyperparameters in the CNN-SVM model to further improve the prediction performance of the CNC machine tool-bearing fault diagnosis model. The results show that the intelligent operation and maintenance and health management method of CNC machine tool bearings proposed in this paper can effectively complete the fault type diagnosis and health status assessment of bearings, and its accuracy index reaches 99.33%. Compared with the single SVM model, Bayes-CNN model, Bayes-SVM model, and CNN-SVM model, the health effect is evaluated. The accuracy is increased by 6.33%, 4.33%, 2.66%, and 1%, respectively. It can be seen that the proposed method can more effectively realize the monitoring and health management of bearing fault.

A High-Speed Train Axle Box Bearing Fault Diagnosis Method Based on Dimension Reduction Fusion and the Optimal Bandpass Filtering Demodulation Spectrum of Multi-Dimensional Signals

The operating state of axle box bearings is crucial to the safety of high-speed trains, and the vibration acceleration signal is a commonly used bearing-health-state monitoring signal. In order to extract hidden characteristic frequency information from the vibration acceleration signal of axle box bearings for fault diagnosis, a method for extracting the fault characteristic frequency based on principal component analysis (PCA) fusion and the optimal bandpass filtered denoising signal analytic energy operator (AEO) demodulation spectrum is proposed in this paper. PCA is used to measure the dimension reduction and fusion of three-direction vibration acceleration, reducing the interference of irrelevant noise components. A new type of multi-channel bandpass filter bank is constructed to obtain filtering signals in different frequency intervals. A new, improved average kurtosis index is used to select the optimal filtering signals for different channel filters in a bandpass filter bank. A dimensionless characteristic index characteristic frequency energy concentration coefficient (CFECC) is proposed for the first time to describe the energy prominence ability of characteristic frequency in the spectrum and can be used to determine the bearing fault type. The effectiveness and applicability of the proposed method are verified using the simulation signals and experimental signals of four fault bearing test cases. The results demonstrate the effectiveness of the proposed method for fault diagnosis and its advantages over other methods.

Analysis of temperature characteristics of high‐speed train wheelset system under complex operating conditions

AbstractWith the rapid advancements in high‐speed train technology, the importance of ensuring the safety of train operations has become paramount. Bearings, being a critical component of train bogies, have garnered significant attention for their role in maintaining safety standards. Monitoring the temperature of bearings to evaluate their motion state is a common practice in high‐speed trains, emphasizing the need for further research into temperature fluctuations. In this study, a dynamic model is developed for the bearing rotor system of high‐speed trains. By considering the contact points between raceways and rolling elements, the power loss in the bearing is obtained and a transient temperature‐field model of the system is established. The relationship between node temperature and factors such as ambient temperature, train running speed, and load is illustrated, with a detailed presentation of the influence of bearing fault type and size on node temperature. The analysis results reveal that the node temperature increases with higher values corresponding to those quantifiable factors and is most affected by rolling element fault. Additionally, it is observed that the temperature rises rapidly in the initial stage and gradually flattens out over time. The comparative analysis of temperature under different fault conditions shows that the node temperature is most affected by the rolling element fault. Experiments and actual line temperature data are used to verify the validity of the model. The comparison results show that the simulation aligns well with experimental and line data. The transient temperature‐field model of the bearing rotor system in high‐speed trains can effectively simulate and predict the temperature change process of each node of the system. The simulation results hold certain theoretical guiding significance for further research and practical applications in ensuring train operation safety.

Adaptive spectrum amplitude modulation method for rolling bearing fault frequency determination

Abstract Signal preprocessing and feature extraction are decisive factors in determining the frequency of bearing faults. The presence of noise interference in the status signal of rolling bearings often hampers accurate fault detection. Although there are various methods for preprocessing vibration signals in rolling bearings, they need further improvement in terms of enhancing fault feature expression and localizing fault frequency bands. This limitation significantly hinders the accuracy of fault frequency determination. In order to enhance the representation of fault information on the frequency spectrum, this study proposes a combined approach that incorporates sparse stacked autoencoder (SSAE), wavelet packet decomposition (WPD), and adaptive spectrum amplitude modulation (ASAM). The resulting method is referred to as SSAE-WPD-ASAM. Firstly, the bearing vibration signal is decomposed by wavelet packet according to the scale and frequency band of the signal. On this basis, the signal reconstruction is realized based on the wavelet packet coefficient and energy distribution in different frequency bands. Secondly, for the whole life cycle signal, the reconstructed signal is self-encoded by sparse stacked autoencoder to achieve dimensionality reduction of the reconstructed signal. Then, the spare reconstructed signal is subjected to ASAM. Finally, through envelope demodulation, peak detection of fault frequency and empirical fault frequency comparison, the specific fault types of rolling bearings are determined. The proposed method is verified by theoretical simulation and three groups of practical experiments. The results show that the proposed method has a significant improvement in diagnostic efficiency and accuracy compared with traditional diagnostic methods.

Multi-resolution short-time Fourier transform providing deep features for 3D CNN to classify rolling bearing fault vibration signals

The time-frequency domain features of vibration signals provide valuable information for deep learning-based rolling bearing fault diagnosis methods, where fault signal classification aiding in the identification of nominal fault types during diagnosis. The Short-Time Fourier Transform (STFT) is a widely used time-frequency transformation method, and its window length is the key parameter that determines the trade-off between time and frequency resolution. The primary motivation of this study is to address the limitation in traditional STFT-based 2D CNN methods: the inability to adapt the window length to different types of signals. To achieve accurate classification of bearing fault types, this study proposes a method based on three-dimensional convolutional neural networks (3D CNNs) to deeply explore the time-frequency domain information of one-dimensional vibration signals from faulty bearings. This method first applies STFT with multiple window sizes to perform multi-resolution time-frequency transformations on the time-domain vibration signals, yielding three-dimensional data. Subsequently, a classifier is trained based on the proposed 3D CNN. Experimental results on public datasets show that, without any sophisticated techniques, the proposed method achieves an average classification accuracy of 99.2% for six types of bearing faults using a relatively simple CNN structure. Compared to 1D CNN and 2D CNN methods that use fixed window sizes for STFT, the proposed method significantly enhances classification performance. Furthermore, it demonstrates robust classification results even on small-scaled bearing datasets.

An intelligent fault diagnosis method for rolling bearing using motor stator current signals

Abstract In the diagnosis of rolling bearing faults, the Motor Current Signature Analysis (MCSA) method offers advantages such as low cost, simplicity, and convenience compared to using vibration signals, temperature information, and other diagnostic objects. However, owing to the interference of high-frequency noise, power frequency, and its harmonics in current signals, which can severely affect the accuracy of bearing fault diagnosis, it is extremely challenging to use the original current signals during bearing faults directly for diagnostic purposes. Therefore, this paper proposes an intelligent fault diagnosis method based on the feature reconstruction (FR) method and convolutional neural networks (CNN). This method can achieve high-precision fault diagnosis using single-phase stator current signals from motors as the diagnostic objects. First, the FR method effectively removes the impact of high-frequency noise, supply frequency, and its harmonics from the current signals, while also highlighting subtle fault feature signals to a certain extent. Second, a CNN suitable for learning the characteristics of the current signals was constructed. Through feature extraction, learning, and classification of the current signal samples processed by the FR method, a diagnostic method with a high classification accuracy was obtained. Visualization techniques were used to present the final diagnosis results intuitively. The experimental results demonstrated the highest diagnostic accuracy and average diagnostic accuracy of the proposed method in diagnosing rolling bearing fault types, with an average diagnostic accuracy of approximately 99% for actual faulty bearing samples.

Identification and Fault Diagnosis of Rolling Element Bearings Using Dimension Theory and Machine Learning Techniques

Abstract The study presents the classification of bearing fault types occurring in rotating machines using machine learning techniques. Recent condition monitoring demands all-inclusive but precise fault diagnosis for industrial machines. The utilization of mathematical modeling with machine learning may be combined for fine fault diagnosis under different working conditions. The current study presents a blend of dimensional analysis (DA) and a K-nearest neighbor (KNN) to diagnose faults in industrial roller bearings. Vibrational responses are collected for several industrial machines under diverse operational conditions. Bearing faults are identified using the DA model with 3.62% error (avg) and classified using KNN with 98.67% accuracy. Comparing the performance of models with experimental and artificial neural networks (ANN) validated the potential of the current approach. The results showed that the KNN demonstrates superior performance in terms of feature prediction and extraction of industrial bearing.

Fault diagnosis of rolling bearing based on SEMD and ISSA-KELMC

Enhancing the operational reliability of rotary machinery relies significantly on the effective diagnosis of faults in rolling bearings. This study introduces an innovative method to improve the accuracy of fault diagnosis of rolling bearings during operation. First, we propose a sine empirical mode decomposition (SEMD) designed to effectively mitigate mode mixing and decompose the vibration signals of rolling bearings into a series of intrinsic mode functions. Subsequently, we constructed and optimized a kernel extreme learning machine classifier (KELMC) using the improved sparrow search algorithm (ISSA). Within ISSA, the opposition-based Learning method is refined and applied to enhance the optimization performance of the sparrow search algorithm. Finally, the paper presents a novel method for the fault diagnosis of rolling bearings based on SEMD and ISSA-KELMC, which can effectively extract the fault features and accurately recognize the fault types of rolling bearings by taking advantage of the SEMD and ISSA-KELMC. The effectiveness of the proposed method was verified through two simulation and fault diagnosis experiments. The results demonstrated the efficiency of the method in diagnosing faults in rolling bearings under both consistent and variable working conditions. This approach is valuable for fault diagnosis and condition monitoring of rotating machinery.

A novel bearing current signal diagnosis method combining variational modal decomposition and improved random forests.

A new fault diagnosis approach based on bearing current signals is proposed in this paper. First, in view of strong background noise of the current signal, the variational modal decomposition method is applied to decompose the bearing current signal to obtain multiple intrinsic mode functions, and then the intrinsic mode functions are constructed as the input feature vector according to the kurtosis. Second, to avoid the influence of random forest parameters on the random forest classifier, a random forest faulty bearing diagnostic model optimized by the whale algorithm is established. Finally, the accuracy rate and confusion matrix are adopted to evaluate the prediction effects of both established and traditional models. The classification accuracy of the real damaged bearing fault type can reach 95.11%. The fault diagnosis accuracy of manually damaged bearings can reach 93.83%. The results show that the method proposed in this paper has high accuracy and good generalization ability for bearing fault diagnosis.

A weighted sparse classification method based on period analysis dictionary

The periodic transient shocks triggered by damages in rolling bearings are frequently overshadowed by disruptive elements such as noise and harmonics. Therefore, the extraction of fault characteristics from these disturbances to identify the health status of the bearing is crucial for fault diagnosis. This study presents a novel approach, the period analysis dictionary weighted sparse representation classification (PAD-WSRC) method, designed specifically for rolling bearings. The proposed approach incorporates Bi-damped wavelet as the dictionary wavelet atom, while accounting for the pulse characteristics induced by faults and leveraging prior knowledge of periodicity. A weighted sparse representation (SR) method was also designed, which calculates the weighted SR coefficients of samples, amplifying the local features of samples while addressing the impact of time-shift bias. In addition, the bearing fault type is identified using a mutual correlation classification criterion based on sparse approximation. Our PAD-WSRC strategy has demonstrated its effectiveness in classifying the health status of bearings across three datasets, achieving recognition accuracies of 99.75%, 99.69% and 99.17%, respectively. Comparisons with several traditional methods further underscore the effectiveness and superiority of our proposed method in classifying rolling bearing faults.

Bearing fault damage degree identification method based on SSA-VMD and Shannon entropy–exponential entropy decision

Aiming at the problem that the weak fault signal of rolling bearing is affected by background noise and the weak fault signal itself leads to the difficulty in extracting fault features, a weak fault diagnosis method of rolling bearing based on sparrow search algorithm-variational mode decomposition (SSA-VMD) and Shannon entropy–exponential entropy decision is proposed. Firstly, the failure energy ratio of the original signal is acquired to judge the bearing failure. Secondly, the original time-domain signal is decomposed by the VMD optimized by SSA-VMD to obtain the Intrinsic Mode Function (IMF) component, and the kurtosis and correlation coefficient are normalized and fused. The fusion parameter ratio (RV) is used to filter the IMF component, and the filtered component is reconstructed to achieve the noise reduction effect. The reconstructed signal is subjected to Hilbert transform to obtain the envelope spectrum of the vibration signal, and the fault type of the bearing can be judged. Finally, the entropy of the reconstructed signal is input into the model based on entropy-multilayer forward neural network (MFNN) to identify the degree of bearing fault damage. The effectiveness of the method is verified by using the experimental data of different fault types of intermediate shaft bearings in Shenyang Aerospace University and the self-built experimental data of outer ring fault detachment evolution. The results show that the fault energy ratio of the original signal is more conducive to judging whether the bearing has a fault than the reconstructed signal. The bearing fault type diagnosis method based on SSA-VMD and parameter fusion screening can effectively identify fault characteristic frequency and its frequency doubling of the inner and outer rings of rolling bearings. The entropy values of different bearing damage signals have different distribution regions, which verify the effectiveness of the bearing fault damage identification method based on entropy–MLP judgement.

A novel method of rolling bearings fault diagnosis based on singular spectrum decomposition and optimized stochastic configuration network

Fault diagnosis of rolling bearings is essential for the safe operation of rotating machinery. However, in the production process, the rolling bearings have a complex working environment embedded with weak fault signals and a large number of interfering signals, which is a considerable challenge to automatically and accurately detect bearing fault type from the actual vibration signal. Therefore, a novel fault diagnosis scheme is proposed based on singular spectrum decomposition (SSD) and an optimized stochastic configuration network (SCN). Firstly, SSD is used to pre-process the original rolling bearings vibration signal to obtain several singular spectral components (SSCs) and the practical component is selected according to the maximum correlation coefficient for signal reconstruction. Furthermore, time domain and power spectrum entropy (PSE) features of the reconstructed signal are extracted to obtain a fault information-rich feature sets. In addition, the parameters of the SCN are optimized by marine predators algorithm (MPA) to enhance the learning ability and generalization performance of the SCN. Finally, the feature sets are input into MPA-SCN to achieve fault classification. Experimental results exhibit that the proposed method has higher accuracy in rolling bearings fault diagnosis compared with other methods, which provides a high-efficiency solution for rolling bearings fault diagnosis.

A dual attention mechanism network with self-attention and frequency channel attention for intelligent diagnosis of multiple rolling bearing fault types

Different fault types of rolling bearings correspond to different features, and classical deep learning models using a single attention mechanism (AM) have limitations in capturing feature diversity. Therefore, a novel dual attention mechanism network (DAMN) with self-attention (SA) and frequency channel attention (FCA) is proposed for rolling bearing fault diagnosis. The SA mechanism is used to capture global relationships between the input features and fault types, and the FCA mechanism applies multi-spectral attention to learn the local useful information among different input channels. The results of the ablation study on the effects of FCA blocks showed that including a proper combination of multiple frequency components is helpful in achieving higher accuracy. Experiments were conducted to diagnose rolling bearings with multiple types of faults. The results show that, compared with current fault diagnosis models, the proposed DAMN has better comprehensive performance in terms of diagnosis accuracy and model convergence speed. It was also demonstrated that the backbone of DAMN based on a dual AM could achieve better performance than the backbone based on a single AM.

A Time–Frequency Residual Convolution Neural Network for the Fault Diagnosis of Rolling Bearings

A time–frequency residual convolution neural network (TFRCNN) was proposed to identify various rolling bearing fault types more efficiently. Three novel points about TFRCNN are presented as follows: First, by constructing a double-branch convolution network in the time domain and the frequency domain, the respective features in the time domain and the frequency domain were extracted to ensure the rich and complete feature representation of raw data sources. Second, specific residual structures were designed to prevent learning degradation of the deep network, and global average pooling was adopted to improve the network’s sparsity. Third, TFRCNN was better than the other models in terms of prediction accuracy, robustness, generalization ability, and convergence. The experimental results demonstrate that the prediction accuracy rate of TFRCNN, trained using mixing load data, reached 98.88 to 99.92% after optimizing the initial learning rate and choosing the optimizer and loss function. It was verified that TFRCNN can adaptively learn to extract deep fault features, accurately identify bearing fault conditions, and overcome the limitations of classical shallow feature extraction and classification methods, as well as common convolution neural networks. Hence, this investigation revealed TFRCNN’s potential for bearing fault diagnosis in practical engineering applications.

An unsupervised transfer learning method based on SOCNN and FBNN and its application on bearing fault diagnosis

In order to improve the ability of the transfer learning model to diagnose similar fault types of bearings in noisy environments, and reduce the dependence of the model on the labeled fault data, an unsupervised transfer learning method based on structure optimized convolutional neural networks and fast batch nuclear-norm maximization (UTL-SOCNN-FBNM) is designed for solving these problems. The method takes advantage of SOCNN to extract the fault features and classify the fault patterns. Meanwhile, the maximum mean difference (MMD) is designed to improve the distribution similarity between the source domain and the target domain. Furthermore, FBNM is utilized to improve the distinguishability and diversity of the target domain batch output matrix. Finally, this method has been applied into bearing fault diagnosis and compared with some various classic methods under different working conditions, the comparison results show that the proposed method obtains highest diagnostic accuracy in 29 out of 30 experimental groups and the highest mean diagnosis accuracies of 5 noise environments, which can accurately identify the fault types and hazard levels of bearings.

Study on the optimization of the classification method of rolling bearing fault type and damage degree based on SFO–VMD

Currently, rolling bearings operate in harsh environments, resulting in acquired signals with a low signal-to-noise ratio. In light of this, this paper proposes an improved variational modal decomposition(VMD) combined with refine composite multi-scale fuzzy entropy (RCMFE) and linear support vector machine (LSVM) for fault diagnosis. Firstly, the sailfish optimization (SFO) algorithm is employed to optimize the important parameter combinations in the VMD algorithm, using the envelope entropy as its objective function. The analysis includes both simulated and real measured signals with varying signal-to-noise ratios. The results demonstrate that, compared to traditional manual parameter setting and empirical modal decomposition methods, this approach effectively addresses the parameter setting issue of VMD in the signal decomposition process. Additionally, it successfully eliminates noise to extract the fault characteristic signal hidden within the original signal. Secondly, the RCMFE algorithm is introduced to overcome the problem of commonly used dimensioned and dimensionless indicators being influenced by load and speed when used as characteristic indicators. By analyzing the influence of load and speed on the RCMFE value, the results demonstrate its strong stability as a feature indicator, unaffected by these factors. For the intelligent classification of failure type and damage degree, LSVM is chosen as the classification method. Analysis results indicate that the distribution characteristics of RCMFE values align better with LSVM compared to the common radial basis function support vector machine, resulting in a significant improvement in diagnosis accuracy.

Non-negative wavelet matrix factorization-based bearing fault intelligent classification method

There are more and more bearing fault types under considering the fault location and degree, and the corresponding fault classification task is becoming increasingly heavy. Raw signals that have not been processed or simply processed are directly input into convolutional neural network (CNN) for classification, resulting in poor classification performance. Aiming at this issue, a time–frequency joint metric feature extraction technique named non-negative wavelet matrix factorization (NWMF) is developed to extract more effective features by comprehensively leveraging the advantages of continuous wavelet transform and non-negative matrix factorization. Based on the NWMF and CNN, an effective intelligent diagnosis framework is constructed to detect bearing fault. In the proposed framework, based on the NWMF, a non-negative basic matrix with smaller size is calculated from the original time–frequency spectrum and it includes bearing fault-related internal core information. In addition, a novel CNN is developed to identify locations and sizes of fault bearing based on the calculated internal core information. For verifying the effectiveness of the proposed framework in handling heavier tasks, the types of bearing faults in the experiments are set up to 15, the results and comparative analysis reveal that the feasibility and superiority of the proposed method are much better than the other traditional machine learning methods and original deep learning methods, such as the support vector machine, random forest and residual neural network.

A fault diagnosis method based on dilated convolution and attention for rolling bearing under multiple working conditions and noisy environments

As essential equipment in rotating machinery, the fault diagnosis technology of rolling bearings has achieved great success. However, it still suffers from limitations in terms of generalization and noise resistance performance when operating under complex conditions. To accurately identify the fault types of rolling bearings under different loads and nosy environments, a novel intelligent fault diagnosis method is proposed. Firstly, the utilization of dilated convolution expands the network's receptive field, thereby effectively enhancing the scope of fault extraction. Then, by incorporating the Efficient Channel Attention (ECA) in different convolutional layers, the extracted features are adaptively recognized, highlighting important representation information and improving fault diagnosis performance. Finally, the proposed network is utilized for rolling bearing fault diagnosis under diverse operating and noise conditions, and its efficacy is evaluated on various datasets. The experimental results demonstrate that the proposed method exhibits good generalization performance and strong robustness, compared with other methods.

Modified locally joint sparse marginal embedding and wasserstein generation adversarial network for bearing fault diagnosis

Rolling bearings are essential parts for manufacturing machines. Vast quantities of features are often extracted from measured signals to comprehensively reflect the conditions of bearings, which may cause high dimensionality, information redundancy, and time consumption. In addition, it is extremely difficult, expensive, and time-consuming to collect samples with label information during the bearing fault diagnosis in real-world scenarios. In this study, a novel bearing defect diagnosis method for small sample size is proposed based on modified local joint sparse marginal embedding (MLJSME) and Wasserstein generative adversarial networks (WGANs). MLJSME can effectively extract intrinsic sparse discriminant features of high-dimensional dataset by preserving both global and local structures. Graph embedding and Gaussian kernel function are adopted to preserve the locality structure of dataset. The global structure and discriminate information are preserved by maximum margin criterion which can also avoid small sample-size problem. Moreover, joint sparsity is applied to preserve the sparse property and improve the robustness to noise and outliers. An abundance of artificial samples can be obtained with WGAN and a few labeled samples. Firstly, a high-dimensional feature dataset consisting of time-domain and frequency-domain features is extracted from original vibration signals, then MLJSME is utilized to extract sensitive low-dimensional features, and a small number of low-dimensional features are fed into WGAN to generate a large number of artificial samples that used to train the classifier, and the bearing fault types can be finally identified. The effectiveness and feasibility of the proposed method is validated by analyzing the different experimental cases.

Fault Diagnosis of Wind Turbine Generators Based on Stacking Integration Algorithm and Adaptive Threshold.

Fault alarm time lag is one of the difficulties in fault diagnosis of wind turbine generators (WTGs), and the existing methods are insufficient to achieve accurate and rapid fault diagnosis of WTGs, and the operation and maintenance costs of WTGs are too high. To invent a new method for fast and accurate fault diagnosis of WTGs, this study constructs a stacking integration model based on the machine learning algorithms light gradient boosting machine (LightGBM), extreme gradient boosting (XGBoost), and stochastic gradient descent regressor (SGDRegressor) using publicly available datasets from Energias De Portugal (EDP). This model is automatically tuned for hyperparameters during training using Bayesian tuning, and the coefficient of determination (R2) and root mean square error (RMSE) were used to evaluate the model to determine its applicability and accuracy. The fitted residuals of the test set were calculated, the Pauta criterion (3σ) and the temporal sliding window were applied, and a final adaptive threshold method for accurate fault diagnosis and alarming was created. The model validation results show that the adaptive threshold method proposed in this study is better than the fixed threshold for diagnosis, and the alarm times for the GENERATOR fault type, GENERATOR_BEARING fault type, and TRANSFORMER fault type are 1.5 h, 5.8 h, and 3 h earlier, respectively.