Domain Adaptive Transfer Learning for Fault Diagnosis

Thanks to digitization of industrial assets in fleets, the ambitious goal of transferring fault diagnosis models fromone machine to the other has raised great interest. Solving these domain adaptive transfer learning tasks has the potential to save large efforts on manually labeling data and modifying models for new machines in the same fleet. Although data-driven methods have shown great potential in fault diagnosis applications, their ability to generalize on new machines and new working conditions are limited because of their tendency to overfit to the training set in reality. One promising solution to this problem is to use domain adaptation techniques. It aims to improve model performance on the target new machine. Inspired by its successful implementation in computer vision, we introduced Domain-Adversarial Neural Networks (DANN) to our context, along with two other popular methods existing in previous fault diagnosis research. We then carefully justify the applicability of these methods in realistic fault diagnosis settings, and offer a unified experimental protocol for a fair comparison between domain adaptation methods for fault diagnosis problems.Comment: Presented at 2019 Prognostics and System Health Management Conference (PHM 2019) in Paris, Franc

불충분한 고장 데이터에 대한 딥러닝 기반 회전 기계 진단기술 학습방법 연구

학위논문(박사)--서울대학교 대학원 :공과대학 기계항공공학부,2020. 2. 윤병동.Deep Learning is a promising approach for fault diagnosis in mechanical applications. Deep learning techniques are capable of processing lots of data in once, and modelling them into desired diagnostic model. In industrial fields, however, we can acquire tons of data but barely useful including fault or failure data because failure in industrial fields is usually unacceptable. To cope with this insufficient fault data problem to train diagnostic model for rotating machinery, this thesis proposes three research thrusts: 1) filter-envelope blocks in convolution neural networks (CNNs) to incorporate the preprocessing steps for vibration signal; frequency filtering and envelope extraction for more optimal solution and reduced efforts in building diagnostic model, 2) cepstrum editing based data augmentation (CEDA) for diagnostic dataset consist of vibration signals from rotating machinery, and 3) selective parameter freezing (SPF) for efficient parameter transfer in transfer learning. The first research thrust proposes noble types of functional blocks for neural networks in order to learn robust feature to the vibration data. Conventional neural networks including convolution neural network (CNN), is tend to learn biased features when the training data is acquired from small cases of conditions. This can leads to unfavorable performance to the different conditions or other similar equipment. Therefore this research propose two neural network blocks which can be incorporated to the conventional neural networks and minimize the preprocessing steps, filter block and envelope block. Each block is designed to learn frequency filter and envelope extraction function respectively, in order to induce the neural network to learn more robust and generalized features from limited vibration samples. The second thrust presents a new data augmentation technique specialized for diagnostic data of vibration signals. Many data augmentation techniques exist for image data with no consideration for properties of vibration data. Conventional techniques for data augmentation, such as flipping, rotating, or shearing are not proper for 1-d vibration data can harm the natural property of vibration signal. To augment vibration data without losing the properties of its physics, the proposed method generate new samples by editing the cepstrum which can be done by adjusting the cepstrum component of interest. By doing reverse transform to the edited cepstrum, the new samples is obtained and this results augmented dataset which leads to higher accuracy for the diagnostic model. The third research thrust suggests a new parameter repurposing method for parameter transfer, which is used for transfer learning. The proposed SPF selectively freezes transferred parameters from source network and re-train only unnecessary parameters for target domain to reduce overfitting and preserve useful source features when the target data is limited to train diagnostic model.딥러닝은 기계 응용 분야의 결함 진단을 위한 유망한 접근 방식이다. 딥러닝 기술은 많은 양의 데이터를 학습하여 진단 모델의 개발을 용이하게 한다. 그러나 산업 분야에서는 많은 양의 데이터를 얻을 수 없거나 얻을 수 있더라도 고장 데이터는 일반적으로 획득하기 매우 어렵기 때문에 딥러닝 방법의 사용은 쉽지 않다. 회전 기계의 진단을 위하여 딥러닝을 학습시킬 때 발생하는 고장 데이터 부족 문제에 대처하기 위해 이 논문은 3 가지 연구를 제안한다. 1) 향상된 진동 특징 학습을 위한 필터-엔벨롭 네트워크 구조 2) 진동데이터 생성을 위한 Cepstrum 기반 데이터 증량법3) 전이 학습에서 효율적인 파라미터 전이를 위한 선택적 파라미터 동결법. 첫 번째 연구는 진동 데이터에 대한 강건한 특징을 배우기 위해 신경망에 대한 새로운 형태의 네트워크 블록들을 제안한다. 합성곱 신경망을 포함하는 종래의 신경망은 학습 데이터가 작은 경우에 데이터로부터 편향된 특징을 배우는 경향이 있으며, 이는 다른 조건에서 작동하는 경우나 다른 시스템에 대해 적용되었을 때 낮은 진단 성능을 보인다. 따라서 본 연구는 기존의 신경망에 함께 사용될 수 있는 필터 블록 및 엔벨롭 블록을 제안한다. 각 블록은 주파수 필터와 엔벨롭 추출 기능을 네트워크 내에서 스스로 학습하여 신경망이 제한된 학습 진동데이터로부터 보다 강건하고 일반화 된 특징을 학습하도록 한다. 두 번째 연구는 진동 신호의 진단 데이터에 특화된 새로운 데이터 증량법을 제안한다. 뒤집기, 회전 또는 전단과 같은 데이터 확대를 위한 이미지 데이터를 위한 기존의 기술이 1 차원 진동 데이터에 적합하지 않으며, 진동 신호의 물리적 특성에 맞지 않는 신호를 생성할 수 있다. 물리적 특성을 잃지 않고 진동 데이터를 증량하기 위해 제안된 방법은 cepstrum의 주요성분을 추출하고 조정하여 역 cepstrum을 수행하는 방식으로 새로운 샘플을 생성한다. 제안된 방법을 통해 데이터를 생성하여 증량돤 데이터세트는 진단 모델 학습에 대해 성능향상을 가져온다. 세 번째 연구는 전이 학습에 사용되는 파라미터 전이를 위한 새로운 파라미터 재학습법을 제안한다. 제안된 선택적 파라미터 동결법은 소스 네트워크에서 전이된 파라미터를 선택적으로 동결하고 대상 도메인에 대해 불필요한 파라미터만 재학습하여 대상 데이터가 진단 모델에 재학습될 때의 과적합을 줄이고 소스 네트워크의 성능을 보존한다. 제안된 세 방법은 독립적으로 또는 동시에 진단모델에 사용되어 부족한 고장데이터로 인한 진단성능의 감소를 경감하거나 더 높은 성능을 이끌어낼 수 있다.Chapter 1 Introduction 13 1.1 Motivation 13 1.2 Research Scope and Overview 15 1.3 Structure of the Thesis 19 Chapter 2 Literature Review 20 2.1 Deep Neural Networks 20 2.2 Transfer Learning and Parameter Transfer 23 Chapter 3 Description of Testbed Data 26 3.1 Bearing Data I: Case Western Reserve University Data 26 3.2 Bearing Data II: Accelerated Life Test Test-bed 27 Chapter 4 Filter-Envelope Blocks in Neural Network for Robust Feature Learning 32 4.1 Preliminary Study of Problems In Use of CNN for Vibration Signals 34 4.1.1 Class Confusion Problem of CNN Model to Different Conditions 34 4.1.2 Benefits of Frequency Filtering and Envelope Extraction for Fault Diagnosis in Vibration Signals 37 4.2 Proposed Network Block 1: Filter Block 41 4.2.1 Spectral Feature Learning in Neural Network 42 4.2.2 FIR Band-pass Filter in Neural Network 45 4.2.3 Result and Discussion 48 4.3 Proposed Neural Block 2: Envelope Block 48 4.3.1 Max-Average Pooling Block for Envelope Extraction 51 4.3.2 Adaptive Average Pooling for Learnable Envelope Extractor 52 4.3.3 Result and Discussion 54 4.4 Filter-Envelope Network for Fault Diagnosis 56 4.4.1 Combinations of Filter-Envelope Blocks for the use of Rolling Element Bearing Fault Diagnosis 56 4.4.2 Summary and Discussion 58 Chapter 5 Cepstrum Editing Based Data Augmentation for Vibration Signals 59 5.1 Brief Review of Data Augmentation for Deep Learning 59 5.1.1 Image Augmentation to Enlarge Training Dataset 59 5.1.2 Data Augmentation for Vibration Signal 61 5.2 Cepstrum Editing based Data Augmentation 62 5.2.1 Cepstrum Editing as a Signal Preprocessing 62 5.2.2 Cepstrum Editing based Data Augmentation 64 5.3 Results and Discussion 65 5.3.1 Performance validation to rolling element bearing diagnosis 65 Chapter 6 Selective Parameter Freezing for Parameter Transfer with Small Dataset 71 6.1 Overall Procedure of Selective Parameter Freezing 72 6.2 Determination Sensitivity of Source Network Parameters 75 6.3 Case Study 1: Transfer to Different Fault Size 76 6.3.1 Performance by hyperparameter α 77 6.3.2 Effect of the number of training samples and network size 79 6.4 Case Study 2: Transfer from Artificial to Natural Fault 81 6.4.1 Diagnostic performance for proposed method 82 6.4.2 Visualization of frozen parameters by hyperparameter α 83 6.4.3 Visual inspection of feature space 85 6.5 Conclusion 87 Chapter 7 91 7.1 Contributions and Significance 91Docto

Information Theory and Its Application in Machine Condition Monitoring

Condition monitoring of machinery is one of the most important aspects of many modern industries. With the rapid advancement of science and technology, machines are becoming increasingly complex. Moreover, an exponential increase of demand is leading an increasing requirement of machine output. As a result, in most modern industries, machines have to work for 24 hours a day. All these factors are leading to the deterioration of machine health in a higher rate than before. Breakdown of the key components of a machine such as bearing, gearbox or rollers can cause a catastrophic effect both in terms of financial and human costs. In this perspective, it is important not only to detect the fault at its earliest point of inception but necessary to design the overall monitoring process, such as fault classification, fault severity assessment and remaining useful life (RUL) prediction for better planning of the maintenance schedule. Information theory is one of the pioneer contributions of modern science that has evolved into various forms and algorithms over time. Due to its ability to address the non-linearity and non-stationarity of machine health deterioration, it has become a popular choice among researchers. Information theory is an effective technique for extracting features of machines under different health conditions. In this context, this book discusses the potential applications, research results and latest developments of information theory-based condition monitoring of machineries

Constructive Incremental Learning for Fault Diagnosis of Rolling Bearings with Ensemble Domain Adaptation

Given the prevalence of rolling bearing fault diagnosis as a practical issue across various working conditions, the limited availability of samples compounds the challenge. Additionally, the complexity of the external environment and the structure of rolling bearings often manifests faults characterized by randomness and fuzziness, hindering the effective extraction of fault characteristics and restricting the accuracy of fault diagnosis. To overcome these problems, this paper presents a novel approach termed constructive Incremental learning-based ensemble domain adaptation (CIL-EDA) approach. Specifically, it is implemented on stochastic configuration networks (SCN) to constructively improve its adaptive performance in multi-domains. Concretely, a cloud feature extraction method is employed in conjunction with wavelet packet decomposition (WPD) to capture the uncertainty of fault information from multiple resolution aspects. Subsequently, constructive Incremental learning-based domain adaptation (CIL-DA) is firstly developed to enhance the cross-domain learning capability of each hidden node through domain matching and construct a robust fault classifier by leveraging limited labeled data from both target and source domains. Finally, fault diagnosis results are obtained by a majority voting of CIL-EDA which integrates CIL-DA and parallel ensemble learning. Experimental results demonstrate that our CIL-DA outperforms several domain adaptation methods and CIL-EDA consistently outperforms state-of-art fault diagnosis methods in few-shot scenarios

Advanced Fault Diagnosis and Health Monitoring Techniques for Complex Engineering Systems

Over the last few decades, the field of fault diagnostics and structural health management has been experiencing rapid developments. The reliability, availability, and safety of engineering systems can be significantly improved by implementing multifaceted strategies of in situ diagnostics and prognostics. With the development of intelligence algorithms, smart sensors, and advanced data collection and modeling techniques, this challenging research area has been receiving ever-increasing attention in both fundamental research and engineering applications. This has been strongly supported by the extensive applications ranging from aerospace, automotive, transport, manufacturing, and processing industries to defense and infrastructure industries

Novel deep cross-domain framework for fault diagnosis or rotary machinery in prognostics and health management

Improving the reliability of engineered systems is a crucial problem in many applications in various engineering fields, such as aerospace, nuclear energy, and water declination industries. This requires efficient and effective system health monitoring methods, including processing and analyzing massive machinery data to detect anomalies and performing diagnosis and prognosis. In recent years, deep learning has been a fast-growing field and has shown promising results for Prognostics and Health Management (PHM) in interpreting condition monitoring signals such as vibration, acoustic emission, and pressure due to its capacity to mine complex representations from raw data. This doctoral research provides a systematic review of state-of-the-art deep learning-based PHM frameworks, an empirical analysis on bearing fault diagnosis benchmarks, and a novel multi-source domain adaptation framework. It emphasizes the most recent trends within the field and presents the benefits and potentials of state-of-the-art deep neural networks for system health management. Besides, the limitations and challenges of the existing technologies are discussed, which leads to opportunities for future research. The empirical study of the benchmarks highlights the evaluation results of the existing models on bearing fault diagnosis benchmark datasets in terms of various performance metrics such as accuracy and training time. The result of the study is very important for comparing or testing new models. A novel multi-source domain adaptation framework for fault diagnosis of rotary machinery is also proposed, which aligns the domains in both feature-level and task-level. The proposed framework transfers the knowledge from multiple labeled source domains into a single unlabeled target domain by reducing the feature distribution discrepancy between the target domain and each source domain. Besides, the model can be easily reduced to a single-source domain adaptation problem. Also, the model can be readily updated to unsupervised domain adaptation problems in other fields such as image classification and image segmentation. Further, the proposed model is modified with a novel conditional weighting mechanism that aligns the class-conditional probability of the domains and reduces the effect of irrelevant source domain which is a critical issue in multi-source domain adaptation algorithms. The experimental verification results show the superiority of the proposed framework over state-of-the-art multi-source domain-adaptation models