Self-adaptive fault diagnosis of roller bearings using infrared thermal images

Fault diagnosis of roller bearings in rotating machinery is of great significance to identify latent abnormalities and failures in industrial plants. This paper presents a new self-adaptive fault diagnosis system for different conditions of roller bearings using InfraRed Thermography (IRT). In the first stage of the proposed system, 2-Dimensional Discrete Wavelet Transform (2D-DWT) and Shannon entropy are applied respectively to decompose images and seek for the desired decomposition level of the approximation coefficients. After that, the histograms of selected coefficients are used as an input of the feature space selection method by using Genetic Algorithm (GA) and Nearest Neighbor (NN), for the purpose of selecting two salient features that can achieve the highest classification accuracy. The results have demonstrated that the proposed scheme can be employed effectively as an intelligent system for bearing fault diagnosis in rotating machinery

Deep learning for infrared thermal image based machine health monitoring

The condition of a machine can automatically be identified by creating and classifying features that summarize characteristics of measured signals. Currently, experts, in their respective fields, devise these features based on their knowledge. Hence, the performance and usefulness depends on the expert's knowledge of the underlying physics or statistics. Furthermore, if new and additional conditions should be detectable, experts have to implement new feature extraction methods. To mitigate the drawbacks of feature engineering, a method from the subfield of feature learning, i.e., deep learning (DL), more specifically convolutional neural networks (NNs), is researched in this paper. The objective of this paper is to investigate if and how DL can be applied to infrared thermal (IRT) video to automatically determine the condition of the machine. By applying this method on IRT data in two use cases, i.e., machinefault detection and oil-level prediction, we show that the proposed system is able to detect many conditions in rotating machinery very accurately (i.e., 95 and 91.67% accuracy for the respective use cases), without requiring any detailed knowledge about the underlying physics, and thus having the potential to significantly simplify condition monitoring using complex sensor data. Furthermore, we show that by using the trained NNs, important regions in the IRT images can be identified related to specific conditions, which can potentially lead to new physical insights

Thermal imaging and vibration-based multisensor fault detection for rotating machinery

In order to minimize operation and maintenance costs and extend the lifetime of rotating machinery, damaging conditions and faults should be detected early and automatically. To enable this, sensor streams should continuously be monitored, processed, and interpreted. In recent years, infrared thermal imaging has gained attention for the said purpose. However, the detection capabilities of a system that uses infrared thermal imaging is limited by the modality captured by this single sensor, as is any single sensor-based system. Hence, within this paper a multisensor system is proposed that not only uses infrared thermal imaging data, but also vibration measurements for automatic condition and fault detection in rotating machinery. It is shown that by combining these two types of sensor data, several conditions/faults and combinations can be detected more accurately than when considering the sensor streams individually

Thermography-based methodology for multifault diagnosis on kinematic chain

The procedures for condition monitoring of electromechanical systems are undergoing a reformulation, mainly, due to the current thermographic affordability of infrared cameras to be incorporated in industrial applications. However, high-performing multifault data-driven methodologies must be investigated in order to infer reliable condition information from the thermal distribution of not only electrical motors but also of shafts and couplings. To address this issue, a novel thermography-based methodology is proposed. First, the infrared capture is processed to obtain a thermographic residual image of the kinematic chain. Second, the thermal distribution of the image's regions of interest is characterized by means of statistical features. Finally, a distributed self-organizing map structure is used to model the nominal thermal distribution to subsequently perform a fault detection and identification. The method provides a reliability quantification of the resulting condition assessment in order to avoid misclassifications and identify the actual fault root-causes. The performance and the effectiveness of the proposed methodology is validated experimentally and compared with the classical maximum temperature gradient procedure.Peer ReviewedPostprint (published version

Multi-Channel Time-Frequency Domain Deep CNN Approach for Machinery Fault Recognition Using Multi-Sensor Time-Series

In the industry, machinery failure causes catastrophic accidents and destructive damage to the machines. It causes the machinery to stop and reduces production, causing financial losses to the industry. As a result, identifying machine faults at an early stage is critical. With the rapid advancement in artificial intelligence-based methods, developing automated systems that can diagnose machinery faults is necessary and challenging. This paper proposes a multi-channel time-frequency domain deep convolutional neural network (CNN)-based approach for machinery fault diagnosis using multivariate time-series data from multisensors (tachometer, microphone, underhang bearing accelerometer, and overhand bearing accelerometer). The wavelet synchro-squeezed transform (WSST) based technique is used to evaluate the time-frequency images from the multivariate time-series data. The time-frequency images are fed into the multi-channel deep CNN model for automated fault detection. The proposed multi-channel deep CNN model is multi-headed, considering the time-frequency domain information of each channel time-series data for automated fault detection. The proposed model’s performance is compared to benchmark models regarding testing accuracy, total parameters, and model size. Experiments have shown that the proposed model outperforms benchmark models regarding classification accuracy. The proposed multi-channel CNN model has obtained the accuracy and F1-score values of 99.48% and 99% for fault classification using time-frequency images of multi-sensor data. Finally, the proposed model’s performance is measured regarding inference time when deployed on edge computing devices such as the Raspberry Pi and the Nvidia Jetson AGX Xavier.publishedVersio

Data-driven imbalance and hard particle detection in rotating machinery using infrared thermal imaging

Currently, temperature-based condition monitoring cannot be used to accurately identify potential faults early in a rotating machines' lifetime since temperature changes are only detectable when the fault escalates. However, currently only point measurements, i.e. thermocouples, are used. In this article, infrared thermal imaging is used which - as opposed to simple thermocouples - provides spatial temperature information. This information proves crucial for the identification of several machine conditions and faults. In this paper the conditions considered are outer-raceway damage in bearings, hard-particle contamination in lubricant and several gradations of shaft imbalance. The fault detection is done using an image processing and machine learning solution which can accurately detect the majority of the faults and conditions in our data set. (C) 2017 Elsevier B.V. All rights reserved

A review of intelligent methods for condition monitoring and fault diagnosis of stator and rotor faults of induction machines

Nowadays, induction motor (IM) is extensively used in industry, including mechanical and electrical applications. However, three main types of IM faults have been discussed in the literature, bearing, stator, and rotor. Importantly, stator and rotor faults represent approximately 50%. Traditional condition monitoring (CM) and fault diagnosis (FD) methods require a high processing cost and much experience knowledge. To tackle this challenge, artificial intelligent (AI) based CM and FD techniques are extensively developed. However, there have been many review research papers for intelligent CM and FD machine learning methods of rolling elements bearings of IM in the literature. Whereas there is a lack in the literature, and there are not many review papers for both stator and rotor intelligent CM and FD. Thus, the proposed study's main contribution is in reviewing the CM and FD of IM, especially for the stator and the rotor, based on AI methods. The paper also provides discussions on the main challenges and possible future works

Methods of condition monitoring and fault detection for electrical machines

publishedVersio

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