Online Bearing Remaining Useful Life Prediction Based on a Novel Degradation Indicator and Convolutional Neural Networks

In industrial applications, nearly half the failures of motors are caused by the degradation of rolling element bearings (REBs). Therefore, accurately estimating the remaining useful life (RUL) for REBs are of crucial importance to ensure the reliability and safety of mechanical systems. To tackle this challenge, model-based approaches are often limited by the complexity of mathematical modeling. Conventional data-driven approaches, on the other hand, require massive efforts to extract the degradation features and construct health index. In this paper, a novel online data-driven framework is proposed to exploit the adoption of deep convolutional neural networks (CNN) in predicting the RUL of bearings. More concretely, the raw vibrations of training bearings are first processed using the Hilbert-Huang transform (HHT) and a novel nonlinear degradation indicator is constructed as the label for learning. The CNN is then employed to identify the hidden pattern between the extracted degradation indicator and the vibration of training bearings, which makes it possible to estimate the degradation of the test bearings automatically. Finally, testing bearings' RULs are predicted by using a $\epsilon$-support vector regression model. The superior performance of the proposed RUL estimation framework, compared with the state-of-the-art approaches, is demonstrated through the experimental results. The generality of the proposed CNN model is also validated by transferring to bearings undergoing different operating conditions

Bearing Health monitoring based on Hilbert-Huang Transform, Support Vector Machine and Regression.

International audienceThe detection, diagnostic and prognostic of bearing degradation play a key role in increasing the reliability and safety of electrical machines especially in key industrial sectors. This paper presents a new approach which combines the Hilbert-Huang transform, the support vector machine and the support vector regression for the monitoring of ball bearings. The proposed approach uses the Hilbert-Huang transform to extract new heath indicators from stationary/non-stationary vibration signals able to tack the degradation of the critical components of bearings. The degradation states are detected by a supervised classification technique called support vector machine and the fault diagnostic is given by analyzing the extracted health indicators. The estimation of the remaining useful life is obtained by a one-step time series prediction based on support vector regression. A set of experimental data collected from degraded bearings is used to validate the proposed approach. Experimental results show that the use of the Hilbert-Huang transform, the support vector machine and the support vector regression is a suitable strategy to improve the detection, diagnostic and prognostic of bearing degradation

Prognostic Approaches Using Transient Monitoring Methods

The utilization of steady state monitoring techniques has become an established means of providing diagnostic and prognostic information regarding both systems and equipment. However, steady state data is not the only, or in some cases, even the best source of information regarding the health and state of a system. Transient data has largely been overlooked as a source of system information due to the additional complexity in analyzing these types of signals. The development for algorithms and techniques to quickly, and intuitively develop generic quantification of deviations a transient signal towards the goal of prognostic predictions has until now, largely been overlooked. By quantifying and trending these shifts, an accurate measure of system heath can be established and utilized by prognostic algorithms. In fact, for some systems the elevated stress levels during transients can provide better, more clear indications of system health than those derived from steady state monitoring. This research is based on the hypothesis that equipment health signals for some failure modes are stronger during transient conditions than during steady-state because transient conditions (e.g. start-up) place greater stress on the equipment for these failure modes. From this it follows that these signals related to the system or equipment health would display more prominent indications of abnormality if one were to know the proper means to identify them. This project seeks to develop methods and conceptual models to monitor transient signals for equipment health. The purpose of this research is to assess if monitoring of transient signals could provide alternate or better indicators of incipient equipment failure prior to steady state signals. The project is focused on identifying methods, both traditional and novel, suitable to implement and test transient model monitoring in both an useful and intuitive way. By means of these techniques, it is shown that the addition information gathered during transient portions of life can be used to either to augment existing steady-state information, or in cases where such information is unavailable, be used as a primary means of developing prognostic models

Development of a machine learning based methodology for bridge health monitoring

Tesi en modalitat de compendi de publicacionsIn recent years the scientific community has been developing new techniques in structural health monitoring (SHM) to identify the damages in civil structures specially in bridges. The bridge health monitoring (BHM) systems serve to reduce overall life-cycle maintenance costs for bridges, as their main objective is to prevent catastrophic failures and damages. In the BHM using dynamic data, there are several problems related to the post-processing of the vibration signals such as: (i) when the modal-based dynamic features like natural frequencies, modes shape and damping are used, they present a limitation in relation to damage location, since they are based on a global response of the structure; (ii) presence of noise in the measurement of vibration responses; (iii) inadequate use of existing algorithms for damage feature extraction because of neglecting the non-linearity and non-stationarity of the recorded signals; (iv) environmental and operational conditions can also generate false damage detections in bridges; (v) the drawbacks of traditional algorithms for processing large amounts of data obtained from the BHM. This thesis proposes new vibration-based parameters and methods with focus on damage detection, localization and quantification, considering a mixed robust methodology that includes signal processing and machine learning methods to solve the identified problems. The increasing volume of bridge monitoring data makes it interesting to study the ability of advanced tools and systems to extract useful information from dynamic and static variables. In the field of Machine Learning (ML) and Artificial Intelligence (AI), powerful algorithms have been developed to face problems where the amount of data is much larger (big data). The possibilities of ML techniques (unsupervised algorithms) were analyzed here in bridges taking into account both operational and environmental conditions. A critical literature review was performed and a deep study of the accuracy and performance of a set of algorithms for detecting damage in three real bridges and one numerical model. In the literature review inherent to the vibration-based damage detection, several state-of-the-art methods have been studied that do not consider the nature of the data and the characteristics of the applied excitation (possible non-linearity, non-stationarity, presence or absence of environmental and/or operational effects) and the noise level of the sensors. Besides, most research uses modal-based damage characteristics that have some limitations. A poor data normalization is performed by the majority of methods and both operational and environmental variability is not properly accounted for. Likewise, the huge amount of data recorded requires automatic procedures with proven capacity to reduce the possibility of false alarms. On the other hand, many investigations have limitations since only numerical or laboratory cases are studied. Therefore, a methodology is proposed by the combination of several algorithms to avoid them. The conclusions show a robust methodology based on ML algorithms capable to detect, localize and quantify damage. It allows the engineers to verify bridges and anticipate significant structural damage when occurs. Moreover, the proposed non-modal parameters show their feasibility as damage features using ambient and forced vibrations. Hilbert-Huang Transform (HHT) in conjunction with Marginal Hilbert Spectrum and Instantaneous Phase Difference shows a great capability to analyze the nonlinear and nonstationary response signals for damage identification under operational conditions. The proposed strategy combines algorithms for signal processing (ICEEMDAN and HHT) and ML (k-means) to conduct damage detection and localization in bridges by using the traffic-induced vibration data in real-time operation.En los últimos años la comunidad científica ha desarrollado nuevas técnicas en monitoreo de salud estructural (SHM) para identificar los daños en estructuras civiles especialmente en puentes. Los sistemas de monitoreo de puentes (BHM) sirven para reducir los costos generales de mantenimiento del ciclo de vida, ya que su principal objetivo es prevenir daños y fallas catastróficas. En el BHM que utiliza datos dinámicos, existen varios problemas relacionados con el procesamiento posterior de las señales de vibración, tales como: (i) cuando se utilizan características dinámicas modales como frecuencias naturales, formas de modos y amortiguamiento, presentan una limitación en relación con la localización del daño, ya que se basan en una respuesta global de la estructura; (ii) presencia de ruido en la medición de las respuestas de vibración; (iii) uso inadecuado de los algoritmos existentes para la extracción de características de daño debido a la no linealidad y la no estacionariedad de las señales registradas; (iv) las condiciones ambientales y operativas también pueden generar falsas detecciones de daños en los puentes; (v) los inconvenientes de los algoritmos tradicionales para procesar grandes cantidades de datos obtenidos del BHM. Esta tesis propone nuevos parámetros y métodos basados en vibraciones con enfoque en la detección, localización y cuantificación de daños, considerando una metodología robusta que incluye métodos de procesamiento de señales y aprendizaje automático. El creciente volumen de datos de monitoreo de puentes hace que sea interesante estudiar la capacidad de herramientas y sistemas avanzados para extraer información útil de variables dinámicas y estáticas. En el campo del Machine Learning (ML) y la Inteligencia Artificial (IA) se han desarrollado potentes algoritmos para afrontar problemas donde la cantidad de datos es mucho mayor (big data). Aquí se analizaron las posibilidades de las técnicas ML (algoritmos no supervisados) teniendo en cuenta tanto las condiciones operativas como ambientales. Se realizó una revisión crítica de la literatura y se llevó a cabo un estudio profundo de la precisión y el rendimiento de un conjunto de algoritmos para la detección de daños en tres puentes reales y un modelo numérico. En la revisión de literatura se han estudiado varios métodos que no consideran la naturaleza de los datos y las características de la excitación aplicada (posible no linealidad, no estacionariedad, presencia o ausencia de efectos ambientales y/u operativos) y el nivel de ruido de los sensores. Además, la mayoría de las investigaciones utilizan características de daño modales que tienen algunas limitaciones. Estos métodos realizan una normalización deficiente de los datos y no se tiene en cuenta la variabilidad operativa y ambiental. Asimismo, la gran cantidad de datos registrados requiere de procedimientos automáticos para reducir la posibilidad de falsas alarmas. Por otro lado, muchas investigaciones tienen limitaciones ya que solo se estudian casos numéricos o de laboratorio. Por ello, se propone una metodología mediante la combinación de varios algoritmos. Las conclusiones muestran una metodología robusta basada en algoritmos de ML capaces de detectar, localizar y cuantificar daños. Permite a los ingenieros verificar puentes y anticipar daños estructurales. Además, los parámetros no modales propuestos muestran su viabilidad como características de daño utilizando vibraciones ambientales y forzadas. La Transformada de Hilbert-Huang (HHT) junto con el Espectro Marginal de Hilbert y la Diferencia de Fase Instantánea muestran una gran capacidad para analizar las señales de respuesta no lineales y no estacionarias para la identificación de daños en condiciones operativas. La estrategia propuesta combina algoritmos para el procesamiento de señales (ICEEMDAN y HHT) y ML (k-means) para detectar y localizar daños en puentes mediante el uso de datos de vibraciones inducidas por el tráfico en tiempo real.Postprint (published version

Linear friction weld process monitoring of fixture cassette deformations using empirical mode decomposition

Due to its inherent advantages, linear friction welding is a solid-state joining process of increasing importance to the aerospace, automotive, medical and power generation equipment industries. Tangential oscillations and forge stroke during the burn-off phase of the joining process introduce essential dynamic forces, which can also be detrimental to the welding process. Since burn-off is a critical phase in the manufacturing stage, process monitoring is fundamental for quality and stability control purposes. This study aims to improve workholding stability through the analysis of fixture cassette deformations. Methods and procedures for process monitoring are developed and implemented in a fail-or-pass assessment system for fixture cassette deformations during the burn-off phase. Additionally, the de-noised signals are compared to results from previous production runs. The observed deformations as a consequence of the forces acting on the fixture cassette are measured directly during the welding process. Data on the linear friction-welding machine are acquired and de-noised using empirical mode decomposition, before the burn-off phase is extracted. This approach enables a direct, objective comparison of the signal features with trends from previous successful welds. The capacity of the whole process monitoring system is validated and demonstrated through the analysis of a large number of signals obtained from welding experiments

Linear friction weld process monitoring of fixture cassette deformations using empirical mode decomposition

Due to its inherent advantages, linear friction welding is a solid-state joining process of increasing importance to the aerospace, automotive, medical and power generation equipment industries. Tangential oscillations and forge stroke during the burn-off phase of the joining process introduce essential dynamic forces, which can also be detrimental to the welding process. Since burn-off is a critical phase in the manufacturing stage, process monitoring is fundamental for quality and stability control purposes. This study aims to improve workholding stability through the analysis of fixture cassette deformations. Methods and procedures for process monitoring are developed and implemented in a fail-or-pass assessment system for fixture cassette deformations during the burn-off phase. Additionally, the de-noised signals are compared to results from previous production runs. The observed deformations as a consequence of the forces acting on the fixture cassette are measured directly during the welding process. Data on the linear friction-welding machine are acquired and de-noised using empirical mode decomposition, before the burn-off phase is extracted. This approach enables a direct, objective comparison of the signal features with trends from previous successful welds. The capacity of the whole process monitoring system is validated and demonstrated through the analysis of a large number of signals obtained from welding experiments

Development of new fault detection methods for rotating machines (roller bearings)

Abstract Early fault diagnosis of roller bearings is extremely important for rotating machines, especially for high speed, automatic and precise machines. Many research efforts have been focused on fault diagnosis and detection of roller bearings, since they constitute one the most important elements of rotating machinery. In this study a combination method is proposed for early damage detection of roller bearing. Wavelet packet transform (WPT) is applied to the collected data for denoising and the resulting clean data are break-down into some elementary components called Intrinsic mode functions (IMFs) using Ensemble empirical mode decomposition (EEMD) method. The normalized energy of three first IMFs are used as input for Support vector machine (SVM) to recognize whether signals are sorting out from healthy or faulty bearings. Then, since there is no robust guide to determine amplitude of added noise in EEMD technique, a new Performance improved EEMD (PIEEMD) is proposed to determine the appropriate value of added noise. A novel feature extraction method is also proposed for detecting small size defect using Teager-Kaiser energy operator (TKEO). TKEO is applied to IMFs obtained to create new feature vectors as input data for one-class SVM. The results of applying the method to acceleration signals collected from an experimental bearing test rig demonstrated that the method can be successfully used for early damage detection of roller bearings. Most of the diagnostic methods that have been developed up to now can be applied for the case stationary working conditions only (constant speed and load). However, bearings often work at time-varying conditions such as wind turbine supporting bearings, mining excavator bearings, vehicles, robots and all processes with run-up and run-down transients. Damage identification for bearings working under non-stationary operating conditions, especially for early/small defects, requires the use of appropriate techniques, which are generally different from those used for the case of stationary conditions, in order to extract fault-sensitive features which are at the same time insensitive to operational condition variations. Some methods have been proposed for damage detection of bearings working under time-varying speed conditions. However, their application might increase the instrumentation cost because of providing a phase reference signal. Furthermore, some methods such as order tracking methods still can be applied when the speed variation is limited. In this study, a novel combined method based on cointegration is proposed for the development of fault features which are sensitive to the presence of defects while in the same time they are insensitive to changes in the operational conditions. It does not require any additional measurements and can identify defects even for considerable speed variations. The signals acquired during run-up condition are decomposed into IMFs using the performance improved EEMD method. Then, the cointegration method is applied to the intrinsic mode functions to extract stationary residuals. The feature vectors are created by applying the Teager-Kaiser energy operator to the obtained stationary residuals. Finally, the feature vectors of the healthy bearing signals are utilized to construct a separating hyperplane using one-class support vector machine. Eventually the proposed method was applied to vibration signals measured on an experimental bearing test rig. The results verified that the method can successfully distinguish between healthy and faulty bearings even if the shaft speed changes dramatically