Incipient fault diagnosis of roller bearing using optimized wavelet transform based multi-speed vibration signatures

Condition monitoring and incipient fault diagnosis of rolling bearing is of great importance to detect failures and ensure reliable operations in rotating machinery. In this paper, a new multi-speed fault diagnostic approach is presented by using self-adaptive wavelet transform components generated from bearing vibration signals. The proposed approach is capable of discriminating signatures from four conditions of rolling bearing, i.e. normal bearing and three different types of defected bearings on outer race, inner race and roller separately. Particle Swarm Optimization (PSO) and Broyden-Fletcher-Goldfarb-Shanno (BFGS) based quasi-Newton minimization algorithms are applied to seek optimal parameters of Impulse Modelling based Continuous Wavelet Transform (IMCWT) model. Then, a three-dimensional feature space of the statistical parameters and a Nearest Neighbor (NN) classifier are respectively applied for fault signature extraction and fault classification. Effectiveness of this approach is then evaluated, and the results have achieved an overall accuracy of 100%. Moreover, the generated discriminatory fault signatures are suitable for multi-speed fault data sets. This technique will be further implemented and tested in a real industrial environment

Fault diagnosis of main engine journal bearing based on vibration analysis using Fisher linear discriminant, K-nearest neighbor and support vector machine

Vibration technique in a machine condition monitoring provides useful reliable information, bringing significant cost benefits to industry. By comparing the signals of a machine running in normal and faulty conditions, detection of defected journal bearings is possible. This paper presents fault diagnosis of a journal bearing based on vibration analysis using three classifiers: Fisher Linear Discriminant (FLD), K-Nearest Neighbor (KNN) and Support Vector Machine (SVM). The frequency-domain vibration signals of an internal combustion engine with intact and defective main journal bearings were obtained. 30 features were extracted by using statistical and vibration parameters. These features were used as inputs to the classifiers. Two different solution methods - variable K value and RBF kernel width (σ) were applied for FLD, KNN and SVM, respectively, in order to achieve the best accuracy. Finally, performance of the three classifiers was calculated in journal bearing fault diagnosis. The results demonstrated that the performance of SVM was significantly better in comparison to FLD and KNN. Also the results confirmed the potential of this procedure in fault diagnosis of journal bearings

Hierarchical k-nearest neighbours classification and binary differential evolution for fault diagnostics of automotive bearings operating under variable conditions

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Closed-Loop Drive Detection and Diagnosis of Multiple Combined Faults in Induction Motor Through Model-Based and Neuro-Fuzzy Network Techniques

In this paper, a fault detection and diagnosis approach adopted for an input-output feedback linearization (IOFL) control of induction motor (IM) drive is proposed. This approach has been employed to detect and identify the simple and mixed broken rotor bars and static air-gap eccentricity faults right from the start its operation by utilizing advanced techniques. Therefore, two techniques are applied: the model-based strategy, which is an online method used to generate residual stator current signal in order to indicate the presence of possible failures by means of the sliding mode observer (SMO) in the closed-loop drive. However, this strategy is not able to recognise the fault types and it can be affected by the other disturbances. Therefore, the offline method using the multi-adaptive neuro-fuzzy inference system (MANAFIS) technique is proposed to identify the faults and distinguish them. However, the MANAFIS required a relevant database to achieve satisfactory results. Hence, the stator current analysis based on the HFFT combination of the Hilbert transform (HT) and Fast Fourier transform (FFT) is applied to extract the amplitude of harmonics due to defects occur and used them as an input data set for the MANFIS under different loads and fault severities. The simulation results show the efficiency of the proposed techniques and its ability to detect and diagnose any minor faults in a closed-loop drive of IM

Condition monitoring of bearing faults using the stator current and shrinkage methods

Producción CientíficaCondition monitoring of bearings is an open issue. The use of the stator current to monitor induction motors has been validated as a very advantageous and practical way to detect several types of faults. Nevertheless, for bearing faults, the use of vibrations or sound generally offers better results in the accuracy of the detection, although with some disadvantages related to the sensors used for monitoring. To improve the performance of bearing monitoring, it is proposed to take advantage of more information available in the current spectra, beyond the usually employed, incorporating the amplitude of a significant number of sidebands around the first eleven harmonics, growing exponentially the number of fault signatures. This is especially interesting for inverter-fed motors. But, in turn, this leads to the problem of overfitting when applying a classifier to perform the fault diagnosis. To overcome this problem, and still exploit all the useful information available in the spectra, it is proposed to use shrinkage methods, which have been lately proposed in machine learning to solve the overfitting issue when the problem has many more variables than examples to classify. A case study with a motor is shown to prove the validity of the proposal.CAPES (process BEX552269/2011-5

Fault Classification of Nonlinear Small Sample Data through Feature Sub-Space Neighbor Vote

The fault classification of a small sample of high dimension is challenging, especially for a nonlinear and non-Gaussian manufacturing process. In this paper, a similarity-based feature selection and sub-space neighbor vote method is proposed to solve this problem. To capture the dynamics, nonlinearity, and non-Gaussianity in the irregular time series data, high order spectral features, and fractal dimension features are extracted, selected, and stacked in a regular matrix. To address the problem of a small sample, all labeled fault data are used for similarity decisions for a specific fault type. The distances between the new data and all fault types are calculated in their feature subspaces. The new data are classified to the nearest fault type by majority probability voting of the distances. Meanwhile, the selected features, from respective measured variables, indicate the cause of the fault. The proposed method is evaluated on a publicly available benchmark of a real semiconductor etching dataset. It is demonstrated that by using the high order spectral features and fractal dimensionality features, the proposed method can achieve more than 84% fault recognition accuracy. The resulting feature subspace can be used to match any new fault data to the fingerprint feature subspace of each fault type, and hence can pinpoint the root cause of a fault in a manufacturing process

Machinery Early Fault Detection Based on Dirichlet Process Mixture Model

© 2013 IEEE. The most commonly used single feature-based anomaly detection method for the complex machinery, such as large wind power equipment, steam turbine generator sets, and reciprocating compressors, exhibits a defect of low-alarm accuracy due to the non-stationary characteristic of the vibration signals. In order to improve the accuracy of fault detection, a novel method based on the Dirichlet process mixture model (DPMM) is proposed. First, the features of the mechanical vibration signals are used to construct the feature space of the equipment. The DPMM modeling method is then applied to self-learn the probabilistic mixture model of the feature space. The normal working condition model is used as the benchmark model. The early fault detection is realized by using a precise difference measurement method based on Kullback-Leibler divergence to calculate the difference between the real-time model and the benchmark model accurately, and by comparing the calculation result with a self-learned alarm threshold. The effectiveness and the adaptability of this novel early fault detection method are verified by comparing it to the single feature-based anomaly detection method and the Gaussian mixture model (GMM)-based early fault detection method