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

Intelligent fault detection and classification based on hybrid deep learning methods for Hardware-in-the-Loop test of automotive software systems

Hardware-in-the-Loop (HIL) has been recommended by ISO 26262 as an essential test bench for determining the safety and reliability characteristics of automotive software systems (ASSs). However, due to the complexity and the huge amount of data recorded by the HIL platform during the testing process, the conventional data analysis methods used for detecting and classifying faults based on the human expert are not realizable. Therefore, the development of effective means based on the historical data set is required to analyze the records of the testing process in an efficient manner. Even though data-driven fault diagnosis is superior to other approaches, selecting the appropriate technique from the wide range of Deep Learning (DL) techniques is challenging. Moreover, the training data containing the automotive faults are rare and considered highly confidential by the automotive industry. Using hybrid DL techniques, this study proposes a novel intelligent fault detection and classification (FDC) model to be utilized during the V-cycle development process, i.e., the system integration testing phase. To this end, an HIL-based real-time fault injection framework is used to generate faulty data without altering the original system model. In addition, a combination of the Convolutional Neural Network (CNN) and Long Short-Term Memory (LSTM) is employed to build the model structure. In this study, eight types of sensor faults are considered to cover the most common potential faults in the signals of ASSs. As a case study, a gasoline engine system model is used to demonstrate the capabilities and advantages of the proposed method and to verify the performance of the model. The results prove that the proposed method shows better detection and classification performance compared to other standalone DL methods. Specifically, the overall detection accuracies of the proposed structure in terms of precision, recall and F1-score are 98.86%, 98.90% and 98.88%, respectively. For classification, the experimental results also demonstrate the superiority under unseen test data with an average accuracy of 98.8%

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

Exploiting gan as an oversampling method for imbalanced data augmentation with application to the fault diagnosis of an industrial robot

O diagnóstico inteligente de falhas baseado em aprendizagem máquina geralmente requer um conjunto de dados balanceados para produzir um desempenho aceitável. No entanto, a obtenção de dados quando o equipamento industrial funciona com falhas é uma tarefa desafiante, resultando frequentemente num desequilíbrio entre dados obtidos em condições nominais e com falhas. As técnicas de aumento de dados são das abordagens mais promissoras para mitigar este problema. Redes adversárias generativas (GAN) são um tipo de modelo generativo que consiste de um módulo gerador e de um discriminador. Por meio de aprendizagem adversária entre estes módulos, o gerador otimizado pode produzir padrões sintéticos que podem ser usados para amumento de dados. Investigamos se asGANpodem ser usadas como uma ferramenta de sobre amostra- -gem para compensar um conjunto de dados desequilibrado em uma tarefa de diagnóstico de falhas num manipulador robótico industrial. Realizaram-se uma série de experiências para validar a viabilidade desta abordagem. A abordagem é comparada com seis cenários, incluindo o método clássico de sobre amostragem SMOTE. Os resultados mostram que a GAN supera todos os cenários comparados. Para mitigar dois problemas reconhecidos no treino das GAN, ou seja, instabilidade de treino e colapso de modo, é proposto o seguinte. Propomos uma generalização da GAN de erro quadrado médio (MSE GAN) da Wasserstein GAN com penalidade de gradiente (WGAN-GP), referida como VGAN (GAN baseado numa matriz V) para mitigar a instabilidade de treino. Além disso, propomos um novo critério para rastrear o modelo mais adequado durante o treino. Experiências com o MNIST e no conjunto de dados do manipulador robótico industrial mostram que o VGAN proposto supera outros modelos competitivos. A rede adversária generativa com consistência de ciclo (CycleGAN) visa lidar com o colapso de modo, uma condição em que o gerador produz pouca ou nenhuma variabilidade. Investigamos a distância fatiada de Wasserstein (SWD) na CycleGAN. O SWD é avaliado tanto no CycleGAN incondicional quanto no CycleGAN condicional com e sem mecanismos de compressão e excitação. Mais uma vez, dois conjuntos de dados são avaliados, ou seja, o MNIST e o conjunto de dados do manipulador robótico industrial. Os resultados mostram que o SWD tem menor custo computacional e supera o CycleGAN convencional.Machine learning based intelligent fault diagnosis often requires a balanced data set for yielding an acceptable performance. However, obtaining faulty data from industrial equipment is challenging, often resulting in an imbalance between data acquired in normal conditions and data acquired in the presence of faults. Data augmentation techniques are among the most promising approaches to mitigate such issue. Generative adversarial networks (GAN) are a type of generative model consisting of a generator module and a discriminator. Through adversarial learning between these modules, the optimised generator can produce synthetic patterns that can be used for data augmentation. We investigate whether GAN can be used as an oversampling tool to compensate for an imbalanced data set in an industrial robot fault diagnosis task. A series of experiments are performed to validate the feasibility of this approach. The approach is compared with six scenarios, including the classical oversampling method (SMOTE). Results show that GAN outperforms all the compared scenarios. To mitigate two recognised issues in GAN training, i.e., instability and mode collapse, the following is proposed. We proposed a generalization of both mean sqaure error (MSE GAN) and Wasserstein GAN with gradient penalty (WGAN-GP), referred to as VGAN (the V-matrix based GAN) to mitigate training instability. Also, a novel criterion is proposed to keep track of the most suitable model during training. Experiments on both the MNIST and the industrial robot data set show that the proposed VGAN outperforms other competitive models. Cycle consistency generative adversarial network (CycleGAN) is aiming at dealing with mode collapse, a condition where the generator yields little to none variability. We investigate the sliced Wasserstein distance (SWD) for CycleGAN. SWD is evaluated in both the unconditional CycleGAN and the conditional CycleGAN with and without squeeze-and-excitation mechanisms. Again, two data sets are evaluated, i.e., the MNIST and the industrial robot data set. Results show that SWD has less computational cost and outperforms conventional CycleGAN

A Comparative Analysis of Deep Learning Convolutional Neural Network Architectures for Fault Diagnosis of Broken Rotor Bars in Induction Motors

[EN] Induction machines (IMs) play a critical role in various industrial processes but are susceptible to degenerative failures, such as broken rotor bars. Effective diagnostic techniques are essential in addressing these issues. In this study, we propose the utilization of convolutional neural networks (CNNs) for detection of broken rotor bars. To accomplish this, we generated a dataset comprising current samples versus angular position using finite element method magnetics (FEMM) software for a squirrel-cage rotor with 28 bars, including scenarios with 0 to 6 broken bars at every possible relative position. The dataset consists of a total of 16,050 samples per motor. We evaluated the performance of six different CNN architectures, namely Inception V4, NasNETMobile, ResNET152, SeNET154, VGG16, and VGG19. Our automatic classification system demonstrated an impressive 99% accuracy in detecting broken rotor bars, with VGG19 performing exceptionally well. Specifically, VGG19 exhibited high accuracy, precision, recall, and F1-Score, with values approaching 0.994 and 0.998. Notably, VGG19 exhibited crucial activations in its feature maps, particularly after domain-specific training, highlighting its effectiveness in fault detection. Comparing CNN architectures assists in selecting the most suitable one for this application based on processing time, effectiveness, and training losses. This research suggests that deep learning can detect broken bars in induction machines with accuracy comparable to that of traditional methods by analyzing current signals using CNNs.K Barrera-Llanga appreciates the financial support of the Secretary of Higher Education, Science, Technology and Innovation of Ecuador as a personal sponsor entity.Barrera-Llanga, K.; Burriel-Valencia, J.; Sapena-Bano, A.; Martinez-Roman, J. (2023). A Comparative Analysis of Deep Learning Convolutional Neural Network Architectures for Fault Diagnosis of Broken Rotor Bars in Induction Motors. Sensors. 23(19):1-20. https://doi.org/10.3390/s23198196120231

Condition Monitoring Methods for Large, Low-speed Bearings

In all industrial production plants, well-functioning machines and systems are required for sustained and safe operation. However, asset performance degrades over time and may lead to reduced effiency, poor product quality, secondary damage to other assets or even complete failure and unplanned downtime of critical systems. Besides the potential safety hazards from machine failure, the economic consequences are large, particularly in offshore applications where repairs are difficult. This thesis focuses on large, low-speed rolling element bearings, concretized by the main swivel bearing of an offshore drilling machine. Surveys have shown that bearing failure in drilling machines is a major cause of rig downtime. Bearings have a finite lifetime, which can be estimated using formulas supplied by the bearing manufacturer. Premature failure may still occur as a result of irregularities in operating conditions and use, lubrication, mounting, contamination, or external environmental factors. On the contrary, a bearing may also exceed the expected lifetime. Compared to smaller bearings, historical failure data from large, low-speed machinery is rare. Due to the high cost of maintenance and repairs, the preferred maintenance arrangement is often condition based. Vibration measurements with accelerometers is the most common data acquisition technique. However, vibration based condition monitoring of large, low-speed bearings is challenging, due to non-stationary operating conditions, low kinetic energy and increased distance from fault to transducer. On the sensor side, this project has also investigated the usage of acoustic emission sensors for condition monitoring purposes. Roller end damage is identified as a failure mode of interest in tapered axial bearings. Early stage abrasive wear has been observed on bearings in drilling machines. The failure mode is currently only detectable upon visual inspection and potentially through wear debris in the bearing lubricant. In this thesis, multiple machine learning algorithms are developed and applied to handle the challenges of fault detection in large, low-speed bearings with little or no historical data and unknown fault signatures. The feasibility of transfer learning is demonstrated, as an approach to speed up implementation of automated fault detection systems when historical failure data is available. Variational autoencoders are proposed as a method for unsupervised dimensionality reduction and feature extraction, being useful for obtaining a health indicator with a statistical anomaly detection threshold. Data is collected from numerous experiments throughout the project. Most notably, a test was performed on a real offshore drilling machine with roller end wear in the bearing. To replicate this failure mode and aid development of condition monitoring methods, an axial bearing test rig has been designed and built as a part of the project. An overview of all experiments, methods and results are given in the thesis, with details covered in the appended papers.publishedVersio

Big Data Analytics for Complex Systems

The evolution of technology in all fields led to the generation of vast amounts of data by modern systems. Using data to extract information, make predictions, and make decisions is the current trend in artificial intelligence. The advancement of big data analytics tools made accessing and storing data easier and faster than ever, and machine learning algorithms help to identify patterns in and extract information from data. The current tools and machines in health, computer technologies, and manufacturing can generate massive raw data about their products or samples. The author of this work proposes a modern integrative system that can utilize big data analytics, machine learning, super-computer resources, and industrial health machines’ measurements to build a smart system that can mimic the human intelligence skills of observations, detection, prediction, and decision-making. The applications of the proposed smart systems are included as case studies to highlight the contributions of each system. The first contribution is the ability to utilize big data revolutionary and deep learning technologies on production lines to diagnose incidents and take proper action. In the current digital transformational industrial era, Industry 4.0 has been receiving researcher attention because it can be used to automate production-line decisions. Reconfigurable manufacturing systems (RMS) have been widely used to reduce the setup cost of restructuring production lines. However, the current RMS modules are not linked to the cloud for online decision-making to take the proper decision; these modules must connect to an online server (super-computer) that has big data analytics and machine learning capabilities. The online means that data is centralized on cloud (supercomputer) and accessible in real-time. In this study, deep neural networks are utilized to detect the decisive features of a product and build a prediction model in which the iFactory will make the necessary decision for the defective products. The Spark ecosystem is used to manage the access, processing, and storing of the big data streaming. This contribution is implemented as a closed cycle, which for the best of our knowledge, no one in the literature has introduced big data analysis using deep learning on real-time applications in the manufacturing system. The code shows a high accuracy of 97% for classifying the normal versus defective items. The second contribution, which is in Bioinformatics, is the ability to build supervised machine learning approaches based on the gene expression of patients to predict proper treatment for breast cancer. In the trial, to personalize treatment, the machine learns the genes that are active in the patient cohort with a five-year survival period. The initial condition here is that each group must only undergo one specific treatment. After learning about each group (or class), the machine can personalize the treatment of a new patient by diagnosing the patients’ gene expression. The proposed model will help in the diagnosis and treatment of the patient. The future work in this area involves building a protein-protein interaction network with the selected genes for each treatment to first analyze the motives of the genes and target them with the proper drug molecules. In the learning phase, a couple of feature-selection techniques and supervised standard classifiers are used to build the prediction model. Most of the nodes show a high-performance measurement where accuracy, sensitivity, specificity, and F-measure ranges around 100%. The third contribution is the ability to build semi-supervised learning for the breast cancer survival treatment that advances the second contribution. By understanding the relations between the classes, we can design the machine learning phase based on the similarities between classes. In the proposed research, the researcher used the Euclidean matrix distance among each survival treatment class to build the hierarchical learning model. The distance information that is learned through a non-supervised approach can help the prediction model to select the classes that are away from each other to maximize the distance between classes and gain wider class groups. The performance measurement of this approach shows a slight improvement from the second model. However, this model reduced the number of discriminative genes from 47 to 37. The model in the second contribution studies each class individually while this model focuses on the relationships between the classes and uses this information in the learning phase. Hierarchical clustering is completed to draw the borders between groups of classes before building the classification models. Several distance measurements are tested to identify the best linkages between classes. Most of the nodes show a high-performance measurement where accuracy, sensitivity, specificity, and F-measure ranges from 90% to 100%. All the case study models showed high-performance measurements in the prediction phase. These modern models can be replicated for different problems within different domains. The comprehensive models of the newer technologies are reconfigurable and modular; any newer learning phase can be plugged-in at both ends of the learning phase. Therefore, the output of the system can be an input for another learning system, and a newer feature can be added to the input to be considered for the learning phase

Sensors Fault Diagnosis Trends and Applications

Fault diagnosis has always been a concern for industry. In general, diagnosis in complex systems requires the acquisition of information from sensors and the processing and extracting of required features for the classification or identification of faults. Therefore, fault diagnosis of sensors is clearly important as faulty information from a sensor may lead to misleading conclusions about the whole system. As engineering systems grow in size and complexity, it becomes more and more important to diagnose faulty behavior before it can lead to total failure. In the light of above issues, this book is dedicated to trends and applications in modern-sensor fault diagnosis

Research on vibration-based early diagnostic system for excavator motor bearing using 1-D CNN

In mining, super-large machines such as rope excavators are used to perform the main mining operations. A rope excavator is equipped with motors that drive mechanisms. Motors are easily damaged as a result of harsh mining conditions. Bearings are important parts in a motor; bearing failure accounts for approximately half of all motor failures. Failure reduces work efficiency and increases maintenance costs. In practice, reactive, preventive, and predictive maintenance are used to minimize failures. Predictive maintenance can prevent failures and is more effective than other maintenance. For effective predictive maintenance, a good diagnosis is required to accurately determine motor-bearing health. In this study, vibration-based diagnosis and a one-dimensional convolutional neural network (1-D CNN) were used to evaluate bearing deterioration levels. The system allows for early diagnosis of bearing failures. Normal and failure-bearing vibrations were measured. Spectral and wavelet analyses were performed to determine the normal and failure vibration features. The measured signals were used to generate new data to represent bearing deterioration in increments of 10%. A reliable diagnosis system was proposed. The proposed system could determine bearing health deterioration at eleven levels with considerable accuracy. Moreover, a new data mixing method was applied