Fault Detection and Diagnosis of Electric Drives Using Intelligent Machine Learning Approaches

Electric motor condition monitoring can detect anomalies in the motor performance which have the potential to result in unexpected failure and financial loss. This study examines different fault detection and diagnosis approaches in induction motors and is presented in six chapters. First, an anomaly technique or outlier detection is applied to increase the accuracy of detecting broken rotor bars. It is shown how the proposed method can significantly improve network reliability by using one-class classification technique. Then, ensemble-based anomaly detection is utilized to compare different methods in ensemble learning in detection of broken rotor bars. Finally, a deep neural network is developed to extract significant features to be used as input parameters of the network. Deep autoencoder is then employed to build an advanced model to make predictions of broken rotor bars and bearing faults occurring in induction motors with a high accuracy

Ensemble learning-based intelligent fault diagnosis method using feature partitioning

Diversity and fusion strategy are the key factors which affect the performance of the ensemble learning systems. In this paper, to tackle the neighborhood factor selecting difficulty of the traditional neighborhood rough set method, the wrapper feature selection algorithm based on kernel neighborhood rough set is introduced to find a set of feature subsets with high diversity, and then a base classifier selection method is proposed for constructing the ensemble learning systems. To increase the diversity, the heterogeneous ensemble learning algorithm based on the proposed base classifier selection method is designed and compared with the similar homogeneous ensemble learning algorithm. To study the effect of the fusion strategy on the final performance of the ensemble learning system, majority voting and D-S theory for fusing the outputs of base classifiers of ensemble learning system to get final decision are compared experimentally. The results on UCI data and the fault signals of rotor-bearing system show that the heterogeneous ensemble learning system with D-S fusion strategy can get the best classifying performance, and the ensemble learning system is superior to single classification system in most cases

AI-enabled modeling and monitoring of data-rich advanced manufacturing systems

The infrastructure of cyber-physical systems (CPS) is based on a meta-concept of cybermanufacturing systems (CMS) that synchronizes the Industrial Internet of Things (IIoTs), Cloud Computing, Industrial Control Systems (ICSs), and Big Data analytics in manufacturing operations. Artificial Intelligence (AI) can be incorporated to make intelligent decisions in the day-to-day operations of CMS. Cyberattack spaces in AI-based cybermanufacturing operations pose significant challenges, including unauthorized modification of systems, loss of historical data, destructive malware, software malfunctioning, etc. However, a cybersecurity framework can be implemented to prevent unauthorized access, theft, damage, or other harmful attacks on electronic equipment, networks, and sensitive data. The five main cybersecurity framework steps are divided into procedures and countermeasure efforts, including identifying, protecting, detecting, responding, and recovering. Given the major challenges in AI-enabled cybermanufacturing systems, three research objectives are proposed in this dissertation by incorporating cybersecurity frameworks. The first research aims to detect the in-situ additive manufacturing (AM) process authentication problem using high-volume video streaming data. A side-channel monitoring approach based on an in-situ optical imaging system is established, and a tensor-based layer-wise texture descriptor is constructed to describe the observed printing path. Subsequently, multilinear principal component analysis (MPCA) is leveraged to reduce the dimension of the tensor-based texture descriptor, and low-dimensional features can be extracted for detecting attack-induced alterations. The second research work seeks to address the high-volume data stream problems in multi-channel sensor fusion for diverse bearing fault diagnosis. This second approach proposes a new multi-channel sensor fusion method by integrating acoustics and vibration signals with different sampling rates and limited training data. The frequency-domain tensor is decomposed by MPCA, resulting in low-dimensional process features for diverse bearing fault diagnosis by incorporating a Neural Network classifier. By linking the second proposed method, the third research endeavor is aligned to recovery systems of multi-channel sensing signals when a substantial amount of missing data exists due to sensor malfunction or transmission issues. This study has leveraged a fully Bayesian CANDECOMP/PARAFAC (FBCP) factorization method that enables to capture of multi-linear interaction (channels × signals) among latent factors of sensor signals and imputes missing entries based on observed signals

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

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

Federated Learning with Uncertainty-Based Client Clustering for Fleet-Wide Fault Diagnosis

Operators from various industries have been pushing the adoption of wireless sensing nodes for industrial monitoring, and such efforts have produced sizeable condition monitoring datasets that can be used to build diagnosis algorithms capable of warning maintenance engineers of impending failure or identifying current system health conditions. However, single operators may not have sufficiently large fleets of systems or component units to collect sufficient data to develop data-driven algorithms. Collecting a satisfactory quantity of fault patterns for safety-critical systems is particularly difficult due to the rarity of faults. Federated learning (FL) has emerged as a promising solution to leverage datasets from multiple operators to train a decentralized asset fault diagnosis model while maintaining data confidentiality. However, there are still considerable obstacles to overcome when it comes to optimizing the federation strategy without leaking sensitive data and addressing the issue of client dataset heterogeneity. This is particularly prevalent in fault diagnosis applications due to the high diversity of operating conditions and system configurations. To address these two challenges, we propose a novel clustering-based FL algorithm where clients are clustered for federating based on dataset similarity. To quantify dataset similarity between clients without explicitly sharing data, each client sets aside a local test dataset and evaluates the other clients' model prediction accuracy and uncertainty on this test dataset. Clients are then clustered for FL based on relative prediction accuracy and uncertainty