A review of intelligent methods for condition monitoring and fault diagnosis of stator and rotor faults of induction machines

Nowadays, induction motor (IM) is extensively used in industry, including mechanical and electrical applications. However, three main types of IM faults have been discussed in the literature, bearing, stator, and rotor. Importantly, stator and rotor faults represent approximately 50%. Traditional condition monitoring (CM) and fault diagnosis (FD) methods require a high processing cost and much experience knowledge. To tackle this challenge, artificial intelligent (AI) based CM and FD techniques are extensively developed. However, there have been many review research papers for intelligent CM and FD machine learning methods of rolling elements bearings of IM in the literature. Whereas there is a lack in the literature, and there are not many review papers for both stator and rotor intelligent CM and FD. Thus, the proposed study's main contribution is in reviewing the CM and FD of IM, especially for the stator and the rotor, based on AI methods. The paper also provides discussions on the main challenges and possible future works

Artificial Neural Network Based Fault Diagnosis of a Pulley-Belt Rotating System

Rotating machines are widely used in various industrial fields. Hence, an unexpected stoppage due to, for example, bad operating conditions or manufacturing error, has safety implications along with economic considerations. In this research, a fault detection system for a pulley-belt rotating system is developed and then different faults simulated in a test rig are investigated. Vibration signal monitoring is utilized since it represents a reliable approach for fault recognition in rotating machinery. Time-domain signal analysis technique is applied to extract some indicative features, such as root mean square, kurtosis and skewness. An artificial neural network (ANN) model is developed to detect the simulated faults. However, in addition to the machine healthy condition five fault types, such as unbalance in the driving pulley, wear in the belt and pulleys misalignment, have been simulated in the test rig. Two MEMS accelerometers (ADXL335), interfaced to Arduino MEGA 2560 as a data acquisition device, are used for vibration amplitude measurement. LabVIEW, which is a graphical programming software, is utilized to develop a signal capturing, analysis and feature extraction system. The result showed the effectiveness of the developed system in detection of different fault types in the pulley-belt system

Entropy Measures in Machine Fault Diagnosis: Insights and Applications

Entropy, as a complexity measure, has been widely applied for time series analysis. One preeminent example is the design of machine condition monitoring and industrial fault diagnostic systems. The occurrence of failures in a machine will typically lead to non-linear characteristics in the measurements, caused by instantaneous variations, which can increase the complexity in the system response. Entropy measures are suitable to quantify such dynamic changes in the underlying process, distinguishing between different system conditions. However, notions of entropy are defined differently in various contexts (e.g., information theory and dynamical systems theory), which may confound researchers in the applied sciences. In this paper, we have systematically reviewed the theoretical development of some fundamental entropy measures and clarified the relations among them. Then, typical entropy-based applications of machine fault diagnostic systems are summarized. Further, insights into possible applications of the entropy measures are explained, as to where and how these measures can be useful towards future data-driven fault diagnosis methodologies. Finally, potential research trends in this area are discussed, with the intent of improving online entropy estimation and expanding its applicability to a wider range of intelligent fault diagnostic systems

Reduction of impacts of oil and gas operations through intelligent maintenance solution

Impacts of oil and gas production operations are always very obvious when there is imbalanced operation, uncontrolled stoppage or catastrophic failure of the system during normal operations. These impacts may range from high flaring and venting of associated petroleum gas, oil release or spillage, equipment damage, fire outbreak to even fatality. Possible causes of imbalanced operations or system failure are categorised into process upset, system degradation, ineffective operation and maintenance procedures and human errors. Effective maintenance strategy integrates major components of the system; people (human factors), operation and maintenance procedures (process) and production plant (technology) to develop an intelligent maintenance solution that is capable of monitoring and detecting fault in the system at incipient stage before operational integrity is compromised. This paper deploys data-based analytics technique to develop condition-based predictive maintenance system to monitor, predict and classify performance of gas processing system. Exhaust gas temperature (EGT) of Gas Turbine Engine (GTE) is one of the operating and control parameters associated with efficiency of the GTE operation. The EGT is measured using several thermocouples, temperature sensors spaced equidistant around the circumference of the exhaust duct of the GTE. Neural network technique of multisensory data fusion is integrated with intelligent maintenance system to monitor performance of GTE, detect fault and classify performance of GTE to optimal, average and abnormal performance

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

Development of new fault detection methods for rotating machines (roller bearings)

Abstract Early fault diagnosis of roller bearings is extremely important for rotating machines, especially for high speed, automatic and precise machines. Many research efforts have been focused on fault diagnosis and detection of roller bearings, since they constitute one the most important elements of rotating machinery. In this study a combination method is proposed for early damage detection of roller bearing. Wavelet packet transform (WPT) is applied to the collected data for denoising and the resulting clean data are break-down into some elementary components called Intrinsic mode functions (IMFs) using Ensemble empirical mode decomposition (EEMD) method. The normalized energy of three first IMFs are used as input for Support vector machine (SVM) to recognize whether signals are sorting out from healthy or faulty bearings. Then, since there is no robust guide to determine amplitude of added noise in EEMD technique, a new Performance improved EEMD (PIEEMD) is proposed to determine the appropriate value of added noise. A novel feature extraction method is also proposed for detecting small size defect using Teager-Kaiser energy operator (TKEO). TKEO is applied to IMFs obtained to create new feature vectors as input data for one-class SVM. The results of applying the method to acceleration signals collected from an experimental bearing test rig demonstrated that the method can be successfully used for early damage detection of roller bearings. Most of the diagnostic methods that have been developed up to now can be applied for the case stationary working conditions only (constant speed and load). However, bearings often work at time-varying conditions such as wind turbine supporting bearings, mining excavator bearings, vehicles, robots and all processes with run-up and run-down transients. Damage identification for bearings working under non-stationary operating conditions, especially for early/small defects, requires the use of appropriate techniques, which are generally different from those used for the case of stationary conditions, in order to extract fault-sensitive features which are at the same time insensitive to operational condition variations. Some methods have been proposed for damage detection of bearings working under time-varying speed conditions. However, their application might increase the instrumentation cost because of providing a phase reference signal. Furthermore, some methods such as order tracking methods still can be applied when the speed variation is limited. In this study, a novel combined method based on cointegration is proposed for the development of fault features which are sensitive to the presence of defects while in the same time they are insensitive to changes in the operational conditions. It does not require any additional measurements and can identify defects even for considerable speed variations. The signals acquired during run-up condition are decomposed into IMFs using the performance improved EEMD method. Then, the cointegration method is applied to the intrinsic mode functions to extract stationary residuals. The feature vectors are created by applying the Teager-Kaiser energy operator to the obtained stationary residuals. Finally, the feature vectors of the healthy bearing signals are utilized to construct a separating hyperplane using one-class support vector machine. Eventually the proposed method was applied to vibration signals measured on an experimental bearing test rig. The results verified that the method can successfully distinguish between healthy and faulty bearings even if the shaft speed changes dramatically

A multitask-aided transfer learning-based diagnostic framework for bearings under inconsistent working conditions.

Rolling element bearings are a vital part of rotating machines and their sudden failure can result in huge economic losses as well as physical causalities. Popular bearing fault diagnosis techniques include statistical feature analysis of time, frequency, or time-frequency domain data. These engineered features are susceptible to variations under inconsistent machine operation due to the non-stationary, non-linear, and complex nature of the recorded vibration signals. To address these issues, numerous deep learning-based frameworks have been proposed in the literature. However, the logical reasoning behind crack severities and the longer training times needed to identify multiple health characteristics at the same time still pose challenges. Therefore, in this work, a diagnosis framework is proposed that uses higher-order spectral analysis and multitask learning (MTL), while also incorporating transfer learning (TL). The idea is to first preprocess the vibration signals recorded from a bearing to look for distinct patterns for a given fault type under inconsistent working conditions, e.g., variable motor speeds and loads, multiple crack severities, compound faults, and ample noise. Later, these bispectra are provided as an input to the proposed MTL-based convolutional neural network (CNN) to identify the speed and the health conditions, simultaneously. Finally, the TL-based approach is adopted to identify bearing faults in the presence of multiple crack severities. The proposed diagnostic framework is evaluated on several datasets and the experimental results are compared with several state-of-the-art diagnostic techniques to validate the superiority of the proposed model under inconsistent working conditions

Bayesian Stochastic Neural Network Model for Turbomachinery Damage Prediction

Turbomachinery often suffers various defects such as impeller cracking, resulting in forced outage, increased maintenance costs, and reduced productivity. Condition monitoring and damage prognostics has been widely used as an increasingly important and powerful tool to improve the system availability, reliability, performance, and maintainability, but still very challenging due to multiple sources of data uncertainties and the complexity of analytics modeling. This paper presents an intelligent probabilistic methodology for anomaly prediction of high-fidelity turbomachine, considering multiple data imperfections and multivariate correlation. The proposed method adeptly integrates several advanced state-of-the-art signal processing and artificial intelligence techniques: wavelet multi-resolution decomposition, Bayesian hypothesis testing, probabilistic principal component analysis, and fuzzy stochastic neural network modeling. The advanced signal processing is employed to reduce dimensionality and to address multivariate correlation and data uncertainty for damage prediction. Instead of conventionally using raw time series data, principal components are utilized in the establishment of stochastic neural network model and anomaly prediction. Bayesian interval hypothesis testing metric is then presented to quantitatively compare the predicted and measured data for model validation and anomaly evaluation, thus providing a confidence indicator to judge the model quality and evaluate the equipment status. Bayesian method is developed in this study for denoising the raw data with multiresolution wavelet decomposition, quantifying the model accuracy, and assessing the equipment status. The dynamic stochastic neural network model is established via the nonlinear autoregressive moving average with exogenous inputs approach. It seamlessly integrates the fuzzy clustering and independent Bernoulli random function into radial basis function neural network. A natural gradient method based on Kullback-Leibler distance criterion is employed to maximize the log-likelihood loss function. The effectiveness of the proposed methodology and procedure is demonstrated with the 11-variable time series data and the forced outage event of a real-world centrifugal compressor