Domain knowledge-informed Synthetic fault sample generation with Health Data Map for cross-domain Planetary Gearbox Fault Diagnosis

Extensive research has been conducted on fault diagnosis of planetary gearboxes using vibration signals and deep learning (DL) approaches. However, DL-based methods are susceptible to the domain shift problem caused by varying operating conditions of the gearbox. Although domain adaptation and data synthesis methods have been proposed to overcome such domain shifts, they are often not directly applicable in real-world situations where only healthy data is available in the target domain. To tackle the challenge of extreme domain shift scenarios where only healthy data is available in the target domain, this paper proposes two novel domain knowledge-informed data synthesis methods utilizing the health data map (HDMap). The two proposed approaches are referred to as scaled CutPaste and FaultPaste. The HDMap is used to physically represent the vibration signal of the planetary gearbox as an image-like matrix, allowing for visualization of fault-related features. CutPaste and FaultPaste are then applied to generate faulty samples based on the healthy data in the target domain, using domain knowledge and fault signatures extracted from the source domain, respectively. In addition to generating realistic faults, the proposed methods introduce scaling of fault signatures for controlled synthesis of faults with various severity levels. A case study is conducted on a planetary gearbox testbed to evaluate the proposed approaches. The results show that the proposed methods are capable of accurately diagnosing faults, even in cases of extreme domain shift, and can estimate the severity of faults that have not been previously observed in the target domain.Comment: Under review / added arXiv identifie

Vibration-based Fault Diagnostics in Wind Turbine Gearboxes Using Machine Learning

A significantly increased production of wind energy offers a path to achieve the goals of green energy policies in the United States and other countries. However, failures in wind turbines and specifically their gearboxes are higher due to their operation in unpredictable wind conditions that result in downtime and losses. Early detection of faults in wind turbines will greatly increase their reliability and commercial feasibility. Recently, data-driven fault diagnosis techniques based on deep learning have gained significant attention due to their powerful feature learning capabilities. Nonetheless, diagnosing faults in wind turbines operating under varying conditions poses a major challenge. Signal components unrelated to faults and high levels of noise obscure the signature generated by early-stage damage. To address this issue, we propose an innovative fault diagnosis framework that utilizes deep learning and leverages cyclostationary analysis of sensor data. By generating cyclic spectral coherence maps from the sensor data, we can emphasize fault-related signatures. These 2D color map representations are then used to train convolutional neural networks capable of detecting even minor faults and early-stage damages. The proposed method is evaluated using test data obtained from multibody dynamic simulations conducted under various operating conditions. The benchmark test cases, inspired by an NREL study, are successfully detected using our approach. To further enhance the accuracy of the model, subsequent studies employ Convolutional Neural Networks with Local Interpretable Model-Agnostic Explanations (LIME). This approach aids in interpreting classifier predictions and developing an interpretable classifier by focusing on a subset range of cyclic spectral coherence maps that carry the unique fault signatures. This improvement contributes to better accuracy, especially in scenarios involving multiple faults in the gearbox that need to be identified. Moreover, to address the challenge of applying this framework in practical settings, where standard deep learning techniques tend to provide inaccurate predictions for unseen faults or unusual operating conditions, we investigate fault diagnostics using a Bayesian convolutional neural network. This approach incorporates uncertainty bounds into prediction results, reducing overconfident misclassifications. The results demonstrate the effectiveness of the Bayesian approach in fault diagnosis, offering valuable implications for condition monitoring in other rotating machinery applications

A Literature Review of Fault Diagnosis Based on Ensemble Learning

The accuracy of fault diagnosis is an important indicator to ensure the reliability of key equipment systems. Ensemble learning integrates different weak learning methods to obtain stronger learning and has achieved remarkable results in the field of fault diagnosis. This paper reviews the recent research on ensemble learning from both technical and field application perspectives. The paper summarizes 87 journals in recent web of science and other academic resources, with a total of 209 papers. It summarizes 78 different ensemble learning based fault diagnosis methods, involving 18 public datasets and more than 20 different equipment systems. In detail, the paper summarizes the accuracy rates, fault classification types, fault datasets, used data signals, learners (traditional machine learning or deep learning-based learners), ensemble learning methods (bagging, boosting, stacking and other ensemble models) of these fault diagnosis models. The paper uses accuracy of fault diagnosis as the main evaluation metrics supplemented by generalization and imbalanced data processing ability to evaluate the performance of those ensemble learning methods. The discussion and evaluation of these methods lead to valuable research references in identifying and developing appropriate intelligent fault diagnosis models for various equipment. This paper also discusses and explores the technical challenges, lessons learned from the review and future development directions in the field of ensemble learning based fault diagnosis and intelligent maintenance

Exploiting generative adversarial networks as an oversampling method for fault diagnosis of an industrial robotic manipulator

Data-driven machine learning techniques play an important role in fault diagnosis, safety, and maintenance of the industrial robotic manipulator. However, these methods require data that, more often that not, are hard to obtain, especially data collected from fault condition states and, without enough and appropriated (balanced) data, no acceptable performance should be expected. Generative adversarial networks (GAN) are receiving a significant interest, especially in the image analysis field due to their outstanding generative capabilities. This paper investigates whether or not GAN can be used as an oversampling tool to compensate for an unbalanced data set in an industrial manipulator fault diagnosis task. A comprehensive empirical analysis is performed taking into account six different scenarios for mitigating the unbalanced data, including classical under and oversampling (SMOTE) methods. In all of these, a wavelet packet transform is used for feature generation while a random forest is used for fault classification. Aspects such as loss functions, learning curves, random input distributions, data shuffling, and initial conditions were also considered. A non-parametric statistical test of hypotheses reveals that all GAN based fault-diagnosis outperforms both under and oversampling classical methods while, within GAN based methods, an average accuracy difference as high as 1.68% can be achieved.FCT-through IDMEC, under LAETA, project UIDB/50022/2020.info:eu-repo/semantics/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

Machine learning for the sustainable energy transition: a data-driven perspective along the value chain from manufacturing to energy conversion

According to the special report Global Warming of 1.5 °C of the IPCC, climate action is not only necessary but more than ever urgent. The world is witnessing rising sea levels, heat waves, events of flooding, droughts, and desertification resulting in the loss of lives and damage to livelihoods, especially in countries of the Global South. To mitigate climate change and commit to the Paris agreement, it is of the uttermost importance to reduce greenhouse gas emissions coming from the most emitting sector, namely the energy sector. To this end, large-scale penetration of renewable energy systems into the energy market is crucial for the energy transition toward a sustainable future by replacing fossil fuels and improving access to energy with socio-economic benefits. With the advent of Industry 4.0, Internet of Things technologies have been increasingly applied to the energy sector introducing the concept of smart grid or, more in general, Internet of Energy. These paradigms are steering the energy sector towards more efficient, reliable, flexible, resilient, safe, and sustainable solutions with huge environmental and social potential benefits. To realize these concepts, new information technologies are required, and among the most promising possibilities are Artificial Intelligence and Machine Learning which in many countries have already revolutionized the energy industry. This thesis presents different Machine Learning algorithms and methods for the implementation of new strategies to make renewable energy systems more efficient and reliable. It presents various learning algorithms, highlighting their advantages and limits, and evaluating their application for different tasks in the energy context. In addition, different techniques are presented for the preprocessing and cleaning of time series, nowadays collected by sensor networks mounted on every renewable energy system. With the possibility to install large numbers of sensors that collect vast amounts of time series, it is vital to detect and remove irrelevant, redundant, or noisy features, and alleviate the curse of dimensionality, thus improving the interpretability of predictive models, speeding up their learning process, and enhancing their generalization properties. Therefore, this thesis discussed the importance of dimensionality reduction in sensor networks mounted on renewable energy systems and, to this end, presents two novel unsupervised algorithms. The first approach maps time series in the network domain through visibility graphs and uses a community detection algorithm to identify clusters of similar time series and select representative parameters. This method can group both homogeneous and heterogeneous physical parameters, even when related to different functional areas of a system. The second approach proposes the Combined Predictive Power Score, a method for feature selection with a multivariate formulation that explores multiple sub-sets of expanding variables and identifies the combination of features with the highest predictive power over specified target variables. This method proposes a selection algorithm for the optimal combination of variables that converges to the smallest set of predictors with the highest predictive power. Once the combination of variables is identified, the most relevant parameters in a sensor network can be selected to perform dimensionality reduction. Data-driven methods open the possibility to support strategic decision-making, resulting in a reduction of Operation & Maintenance costs, machine faults, repair stops, and spare parts inventory size. Therefore, this thesis presents two approaches in the context of predictive maintenance to improve the lifetime and efficiency of the equipment, based on anomaly detection algorithms. The first approach proposes an anomaly detection model based on Principal Component Analysis that is robust to false alarms, can isolate anomalous conditions, and can anticipate equipment failures. The second approach has at its core a neural architecture, namely a Graph Convolutional Autoencoder, which models the sensor network as a dynamical functional graph by simultaneously considering the information content of individual sensor measurements (graph node features) and the nonlinear correlations existing between all pairs of sensors (graph edges). The proposed neural architecture can capture hidden anomalies even when the turbine continues to deliver the power requested by the grid and can anticipate equipment failures. Since the model is unsupervised and completely data-driven, this approach can be applied to any wind turbine equipped with a SCADA system. When it comes to renewable energies, the unschedulable uncertainty due to their intermittent nature represents an obstacle to the reliability and stability of energy grids, especially when dealing with large-scale integration. Nevertheless, these challenges can be alleviated if the natural sources or the power output of renewable energy systems can be forecasted accurately, allowing power system operators to plan optimal power management strategies to balance the dispatch between intermittent power generations and the load demand. To this end, this thesis proposes a multi-modal spatio-temporal neural network for multi-horizon wind power forecasting. In particular, the model combines high-resolution Numerical Weather Prediction forecast maps with turbine-level SCADA data and explores how meteorological variables on different spatial scales together with the turbines' internal operating conditions impact wind power forecasts. The world is undergoing a third energy transition with the main goal to tackle global climate change through decarbonization of the energy supply and consumption patterns. This is not only possible thanks to global cooperation and agreements between parties, power generation systems advancements, and Internet of Things and Artificial Intelligence technologies but also necessary to prevent the severe and irreversible consequences of climate change that are threatening life on the planet as we know it. This thesis is intended as a reference for researchers that want to contribute to the sustainable energy transition and are approaching the field of Artificial Intelligence in the context of renewable energy systems