Real-Time Vibration-Based Bearing Fault Diagnosis Under Time-Varying Speed Conditions

Detection of rolling-element bearing faults is crucial for implementing proactive maintenance strategies and for minimizing the economic and operational consequences of unexpected failures. However, many existing techniques are developed and tested under strictly controlled conditions, limiting their adaptability to the diverse and dynamic settings encountered in practical applications. This paper presents an efficient real-time convolutional neural network (CNN) for diagnosing multiple bearing faults under various noise levels and time-varying rotational speeds. Additionally, we propose a novel Fisher-based spectral separability analysis (SSA) method to elucidate the effectiveness of the designed CNN model. We conducted experiments on both healthy bearings and bearings afflicted with inner race, outer race, and roller ball faults. The experimental results show the superiority of our model over the current state-of-the-art approach in three folds: it achieves substantial accuracy gains of up to 15.8%, it is robust to noise with high performance across various signal-to-noise ratios, and it runs in real-time with processing durations five times less than acquisition. Additionally, by using the proposed SSA technique, we offer insights into the model's performance and underscore its effectiveness in tackling real-world challenges

Machine learning and deep learning based methods toward Industry 4.0 predictive maintenance in induction motors: Α state of the art survey

Purpose: Developments in Industry 4.0 technologies and Artificial Intelligence (AI) have enabled data-driven manufacturing. Predictive maintenance (PdM) has therefore become the prominent approach for fault detection and diagnosis (FD/D) of induction motors (IMs). The maintenance and early FD/D of IMs are critical processes, considering that they constitute the main power source in the industrial production environment. Machine learning (ML) methods have enhanced the performance and reliability of PdM. Various deep learning (DL) based FD/D methods have emerged in recent years, providing automatic feature engineering and learning and thereby alleviating drawbacks of traditional ML based methods. This paper presents a comprehensive survey of ML and DL based FD/D methods of IMs that have emerged since 2015. An overview of the main DL architectures used for this purpose is also presented. A discussion of the recent trends is given as well as future directions for research. Design/methodology/approach: A comprehensive survey has been carried out through all available publication databases using related keywords. Classification of the reviewed works has been done according to the main ML and DL techniques and algorithms Findings: DL based PdM methods have been mainly introduced and implemented for IM fault diagnosis in recent years. Novel DL FD/D methods are based on single DL techniques as well as hybrid techniques. DL methods have also been used for signal preprocessing and moreover, have been combined with traditional ML algorithms to enhance the FD/D performance in feature engineering. Publicly available datasets have been mostly used to test the performance of the developed methods, however industrial datasets should become available as well. Multi-agent system (MAS) based PdM employing ML classifiers has been explored. Several methods have investigated multiple IM faults, however, the presence of multiple faults occurring simultaneously has rarely been investigated. Originality/value: The paper presents a comprehensive review of the recent advances in PdM of IMs based on ML and DL methods that have emerged since 2015Peer Reviewe

Bearing Fault Diagnosis Based on Wide Deep Convolutional Neural Network and Long Short Term Memory

Mechanical fault can cause economic loss of different degrees, even casualties. Timely fault diagnosis is an essential condition for ensuring safe production in modern industry. With the growth of intelligent manufacturing, more and more attention is paid to fault diagnosis methods that are based on deep learning. However, the diagnostic accuracy of existing diagnostic methods has still to be improved. Therefore, a fault diagnosis method called WDCNN-LSTM is proposed by combining Wide First-layer Deep Convolutional Neural Network with Long and Short Term Memory. Feature information is extracted adaptively from one-dimensional original vibration signals by Convolutional Neural Network. The extracted features are further extracted by Long and Short Term Memory, so that the fault feature information can be fully obtained. Experiments are performed on CWRU datasets to verify our proposed method. By analyzing the experimental results, we find that the average accuracy of the proposed WDCNN-LSTM model is 99.65%

Active Foundational Models for Fault Diagnosis of Electrical Motors

Fault detection and diagnosis of electrical motors are of utmost importance in ensuring the safe and reliable operation of several industrial systems. Detection and diagnosis of faults at the incipient stage allows corrective actions to be taken in order to reduce the severity of faults. The existing data-driven deep learning approaches for machine fault diagnosis rely extensively on huge amounts of labeled samples, where annotations are expensive and time-consuming. However, a major portion of unlabeled condition monitoring data is not exploited in the training process. To overcome this limitation, we propose a foundational model-based Active Learning framework that utilizes less amount of labeled samples, which are most informative and harnesses a large amount of available unlabeled data by effectively combining Active Learning and Contrastive Self-Supervised Learning techniques. It consists of a transformer network-based backbone model trained using an advanced nearest-neighbor contrastive self-supervised learning method. This approach empowers the backbone to learn improved representations of samples derived from raw, unlabeled vibration data. Subsequently, the backbone can undergo fine-tuning to address a range of downstream tasks, both within the same machines and across different machines. The effectiveness of the proposed methodology has been assessed through the fine-tuning of the backbone for multiple target tasks using three distinct machine-bearing fault datasets. The experimental evaluation demonstrates a superior performance as compared to existing state-of-the-art fault diagnosis methods with less amount of labeled data.Comment: 30 pages, 2 figures, 7 table

Dconformer: A denoising convolutional transformer with joint learning strategy for intelligent diagnosis of bearing faults

Rolling bearings are the core components of rotating machinery, and their normal operation is crucial to entire industrial applications. Most existing condition monitoring methods have been devoted to extracting discriminative features from vibration signals that reflect bearing health status. However, the complex working conditions of rolling bearings often make the fault-related information easily buried in noise and other interference. Therefore, it is challenging for existing approaches to extract sufficient critical features in these scenarios. To address this issue, this paper proposes a novel CNN-Transformer network, referred to as Dconformer, capable of extracting both local and global discriminative features from noisy vibration signals. The main contributions of this research include: (1) Developing a novel joint-learning strategy that simultaneously enhances the performance of signal denoising and fault diagnosis, leading to robust and accurate diagnostic results; (2) Constructing a novel CNN-transformer network with a multi-branch cross-cascaded architecture, which inherits the strengths of CNNs and transformers and demonstrates superior anti-interference capability. Extensive experimental results reveal that the proposed Dconformer outperforms five state-of-the-art approaches, particularly in strong noisy scenarios

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

Advanced Process Monitoring for Industry 4.0

This book reports recent advances on Process Monitoring (PM) to cope with the many challenges raised by the new production systems, sensors and “extreme data” conditions that emerged with Industry 4.0. Concepts such as digital-twins and deep learning are brought to the PM arena, pushing forward the capabilities of existing methodologies to handle more complex scenarios. The evolution of classical paradigms such as Latent Variable modeling, Six Sigma and FMEA are also covered. Applications span a wide range of domains such as microelectronics, semiconductors, chemicals, materials, agriculture, as well as the monitoring of rotating equipment, combustion systems and membrane separation processes

The blessings of explainable AI in operations & maintenance of wind turbines

Wind turbines play an integral role in generating clean energy, but regularly suffer from operational inconsistencies and failures leading to unexpected downtimes and significant Operations & Maintenance (O&M) costs. Condition-Based Monitoring (CBM) has been utilised in the past to monitor operational inconsistencies in turbines by applying signal processing techniques to vibration data. The last decade has witnessed growing interest in leveraging Supervisory Control & Acquisition (SCADA) data from turbine sensors towards CBM. Machine Learning (ML) techniques have been utilised to predict incipient faults in turbines and forecast vital operational parameters with high accuracy by leveraging SCADA data and alarm logs. More recently, Deep Learning (DL) methods have outperformed conventional ML techniques, particularly for anomaly prediction. Despite demonstrating immense promise in transitioning to Artificial Intelligence (AI), such models are generally black-boxes that cannot provide rationales behind their predictions, hampering the ability of turbine operators to rely on automated decision making. We aim to help combat this challenge by providing a novel perspective on Explainable AI (XAI) for trustworthy decision support.This thesis revolves around three key strands of XAI – DL, Natural Language Generation (NLG) and Knowledge Graphs (KGs), which are investigated by utilising data from an operational turbine. We leverage DL and NLG to predict incipient faults and alarm events in the turbine in natural language as well as generate human-intelligible O&M strategies to assist engineers in fixing/averting the faults. We also propose specialised DL models which can predict causal relationships in SCADA features as well as quantify the importance of vital parameters leading to failures. The thesis finally culminates with an interactive Question- Answering (QA) system for automated reasoning that leverages multimodal domain-specific information from a KG, facilitating engineers to retrieve O&M strategies with natural language questions. By helping make turbines more reliable, we envisage wider adoption of wind energy sources towards tackling climate change