Blade fault diagnosis using artificial intelligence technique

Blade fault diagnosis is conventionally based on interpretation of vibration spectrum and wavelet map. These methods are however found to be difficult and subjective as it requires visual interpretation of chart and wavelet color map. To overcome this problem, important features for blade fault diagnosis in a multi row of rotor blade system was selected to develop a novel blade fault diagnosis method based on artificial intelligence techniques to reduce subjective interpretation. Three artificial neural network models were developed to detect blade fault, classify the type of blade fault, and locate the blade fault location. An experimental study was conducted to simulate different types of blade faults involving blade rubbing, loss of blade part, and twisted blade. Vibration signals for all blade fault conditions were measured with a sampling rate of 5 kHz under steady-state conditions at a constant rotating speed. Continuous wavelet transform was used to analyse the vibration signals and its results were used subsequently for feature extraction. Statistical features were extracted from the continuous wavelet coefficients of the rotor operating frequency and its corresponding blade passing frequencies. The extracted statistical features were grouped into three different feature sets. In addition, two new feature sets were proposed: blade statistical curve area and blade statistical summation. The effectiveness of the five different feature sets for blade fault detection, classification, and localisation was investigated. Classification results showed that the statistical features extracted from the operating frequency to be more effective for blade fault detection, classification, and localisation than the statistical features from blade passing frequencies. Feature sets of blade statistical curve area was found to be more effective for blade fault classification, while feature sets of blade statistical summation were more effective for blade fault localisation. The application of feature selection using genetic algorithm showed good accuracy performance with fewer features achieved. The neural network developed for blade fault detection, classification, and localisation achieved accuracy of 100%, 98.15% and 83.47% respectively. With the developed blade fault diagnosis methods, manual interpretation solely dependent on knowledge and the experience of individuals can be reduced. The novel methods can therefore be used as an alternative method for blade fault diagnosis

Roller element bearing acoustic fault detection using smartphone and consumer microphones

Roller element bearings are a common component and crucial to most rotating machinery; their failure makes up around half of the total machine failures, each with the potential to cause extreme damage, injury and downtime. Fault detection through condition monitoring is of significant importance. This paper demonstrates bearing fault detection using widely accessible consumer audio tools. Audio measurements from a smartphone and a standard USB microphone, and vibration measurements from an accelerometer are collected during tests on an electrical induction machine exhibiting a variety of mechanical bearing anomalies. A peak finding method along with use of trained Support Vector Machines (SVMs) classify the faults. It is shown that the classification rate from both the smartphone and the USB microphone was 95 and 100%, respectively, with the direct physically detected vibration results achieving only 75% classification accuracy. This work opens up the opportunity of using readily affordable and accessible acoustic diagnosis and prognosis for early mechanical anomalies on rotating machines

Acoustic Condition Monitoring & Fault Diagnostics for Industrial Systems

Condition monitoring and fault diagnostics for industrial systems is required for cost reduction, maintenance scheduling, and reducing system failures. Catastrophic failure usually causes significant damage and may cause injury or fatality, making early and accurate fault diagnostics of paramount importance. Existing diagnostics can be improved by augmenting or replacing with acoustic measurements, which have proven advantages over more traditional vibration measurements including, earlier detection of emerging faults, increased diagnostic accuracy, remote sensors and easier setup and operation. However, industry adoption of acoustics remains in relative infancy due to vested confidence and reliance on existing measurement and, perceived difficulties with noise contamination and diagnostic accuracy. Researched acoustic monitoring examples typically employ specialist surface-mount transducers, signal amplification, and complex feature extraction and machine learning algorithms, focusing on noise rejection and fault classification. Usually, techniques are fine-tuned to maximise diagnostic performance for the given problem. The majority investigate mechanical fault modes, particularly Roller Element Bearings (REBs), owing to the mechanical impacts producing detectable acoustic waves. The first contribution of this project is a suitability study into the use of low-cost consumer-grade acoustic sensors for fault diagnostics of six different REB health conditions, comparing against vibration measurements. Experimental results demonstrate superior acoustic performance throughout but particularly at lower rotational speed and axial load. Additionally, inaccuracies caused by dynamic operational parameters (speed in this case), are minimised by novel multi-Support Vector Machine training. The project then expands on existing work to encompass diagnostics for a previously unreported electrical fault mode present on a Brush-Less Direct Current motor drive system. Commonly studied electrical faults, such as a broken rotor bar or squirrel cage, result from mechanical component damage artificially seeded and not spontaneous. Here, electrical fault modes are differentiated as faults caused by issues with the power supply, control system or software (not requiring mechanical damage or triggering intervention). An example studied here is a transient current instability, generated by non-linear interaction of the motor electrical parameters, parasitic components and digital controller realisation. Experimental trials successfully demonstrate real-time feature extraction and further validate consumer-grade sensors for industrial system diagnostics. Moreover, this marks the first known diagnosis of an electrically-seeded fault mode as defined in this work. Finally, approaching an industry-ready diagnostic system, the newly released PYNQ-Z2 Field Programmable Gate Array is used to implement the first known instance of multiple feature extraction algorithms that operate concurrently in continuous real-time. A proposed deep-learning algorithm can analyse the features to determine the optimum feature extraction combination for ongoing continuous monitoring. The proposed black-box, all-in-one solution, is capable of accurate unsupervised diagnostics on almost any application, maintaining excellent diagnostic performance. This marks a major leap forward from fine-tuned feature extraction performed offline for artificially seeded mechanical defects to multiple real-time feature extraction demonstrated on a spontaneous electrical fault mode with a versatile and adaptable system that is low-cost, readily available, with simple setup and operation. The presented concept represents an industry-ready all-in-one acoustic diagnostic solution, that is hoped to increase adoption of acoustic methods, greatly improving diagnostics and minimising catastrophic failures

Advances in Automated Driving Systems

Electrification, automation of vehicle control, digitalization and new mobility are the mega-trends in automotive engineering, and they are strongly connected. While many demonstrations for highly automated vehicles have been made worldwide, many challenges remain in bringing automated vehicles to the market for private and commercial use. The main challenges are as follows: reliable machine perception; accepted standards for vehicle-type approval and homologation; verification and validation of the functional safety, especially at SAE level 3+ systems; legal and ethical implications; acceptance of vehicle automation by occupants and society; interaction between automated and human-controlled vehicles in mixed traffic; human–machine interaction and usability; manipulation, misuse and cyber-security; the system costs of hard- and software and development efforts. This Special Issue was prepared in the years 2021 and 2022 and includes 15 papers with original research related to recent advances in the aforementioned challenges. The topics of this Special Issue cover: Machine perception for SAE L3+ driving automation; Trajectory planning and decision-making in complex traffic situations; X-by-Wire system components; Verification and validation of SAE L3+ systems; Misuse, manipulation and cybersecurity; Human–machine interactions, driver monitoring and driver-intention recognition; Road infrastructure measures for the introduction of SAE L3+ systems; Solutions for interactions between human- and machine-controlled vehicles in mixed traffic