Information Theory and Its Application in Machine Condition Monitoring

Condition monitoring of machinery is one of the most important aspects of many modern industries. With the rapid advancement of science and technology, machines are becoming increasingly complex. Moreover, an exponential increase of demand is leading an increasing requirement of machine output. As a result, in most modern industries, machines have to work for 24 hours a day. All these factors are leading to the deterioration of machine health in a higher rate than before. Breakdown of the key components of a machine such as bearing, gearbox or rollers can cause a catastrophic effect both in terms of financial and human costs. In this perspective, it is important not only to detect the fault at its earliest point of inception but necessary to design the overall monitoring process, such as fault classification, fault severity assessment and remaining useful life (RUL) prediction for better planning of the maintenance schedule. Information theory is one of the pioneer contributions of modern science that has evolved into various forms and algorithms over time. Due to its ability to address the non-linearity and non-stationarity of machine health deterioration, it has become a popular choice among researchers. Information theory is an effective technique for extracting features of machines under different health conditions. In this context, this book discusses the potential applications, research results and latest developments of information theory-based condition monitoring of machineries

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

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 Digital Triplet for Utilizing Offline Environments to Train Condition Monitoring Systems for Rolling Element Bearings

Manufacturing competitiveness is related to making a quality product while incurring the lowest costs. Unexpected downtime caused by equipment failure negatively impacts manufacturing competitiveness due to the ensuing defects and delays caused by the downtime. Manufacturers have adopted condition monitoring (CM) techniques to reduce unexpected downtime to augment maintenance strategies. The CM adoption has transitioned maintenance from Breakdown Maintenance (BM) to Condition-Based Maintenance (CbM) to anticipate impending failures and provide maintenance actions before equipment failure. CbM is the umbrella term for maintenance strategies that use condition monitoring techniques such as Preventive Maintenance (PM) and Predictive Maintenance (PdM). Preventive Maintenance involves providing periodic checks based on either time or sensory input. Predictive Maintenance utilizes continuous or periodic sensory inputs to determine the machine health state to predict the equipment failure. The overall goal of the work is to improve bearing diagnostic and prognostic predictions for equipment health by utilizing surrogate systems to generate failure data that represents production equipment failure, thereby providing training data for condition monitoring solutions without waiting for real world failure data. This research seeks to address the challenges of obtaining failure data for CM systems by incorporating a third system into monitoring strategies to create a Digital Triplet (DTr) for condition monitoring to increase the amount of possible data for condition monitoring. Bearings are a critical component in rotational manufacturing systems with wide application to other industries outside of manufacturing, such as energy and defense. The reinvented DTr system considers three components: the physical, surrogate, and digital systems. The physical system represents the real-world application in production that cannot fail. The surrogate system represents a physical component in a test system in an offline environment where data is generated to fill in gaps from data unavailable in the real-world system. The digital system is the CM system, which provides maintenance recommendations based on the ingested data from the real world and surrogate systems. In pursuing the research goal, a comprehensive bearing dataset detailing these four failure modes over different collection operating parameters was created. Subsequently, the collections occurred under different operating conditions, such as speed-varying, load-varying, and steadystate. Different frequency and time measures were used to analyze and identify differentiating criteria between the different failure classes over the differing operating conditions. These empirical observations were recreated using simulations to filter out potential outliers. The outputs of the physical model were combined with knowledge from the empirical observations to create ”spectral deltas” to augment existing bearing data and create new failure data that resemble similar frequency criteria to the original data. The primary verification occurred on a laboratory-bearing test stand. A conjecture is provided on how to scale to a larger system by analyzing a larger system from a local manufacturer. From the subsequent analysis of machine learning diagnosis and prognosis models, the original and augmented bearing data can complement each other during model training. The subsequent data substitution verifies that bearing data collected under different operating conditions and sizes can be substituted between different systems. Ostensibly, the full formulation of the digital triplet system is that bearing data generated at a smaller size can be scaled to train predictive failure models for larger bearing sizes. Future work should consider implementing this method for other systems outside of bearings, such as gears, non-rotational equipment, such as pumps, or even larger complex systems, such as computer numerically controlled machine tools or car engines. In addition, the method and process should not be restricted to only mechanical systems and could be applied to electrical systems, such as batteries. Furthermore, an investigation should consider further data-driven approximations to specific bearing characteristics related to the stiffness and damping parameters needed in modeling. A final consideration is for further investigation into the scalability quantities within the data and how to track these changes through different system levels

Challenges and opportunities of deep learning models for machinery fault detection and diagnosis: a review

In the age of industry 4.0, deep learning has attracted increasing interest for various research applications. In recent years, deep learning models have been extensively implemented in machinery fault detection and diagnosis (FDD) systems. The deep architecture's automated feature learning process offers great potential to solve problems with traditional fault detection and diagnosis (TFDD) systems. TFDD relies on manual feature selection, which requires prior knowledge of the data and is time intensive. However, the high performance of deep learning comes with challenges and costs. This paper presents a review of deep learning challenges related to machinery fault detection and diagnosis systems. The potential for future work on deep learning implementation in FDD systems is briefly discussed

A Novel Feature Selection Scheme and a Diversified-Input SVM-Based Classifier for Sensor Fault Classification

The efficiency of a binary support vector machine- (SVM-) based classifier depends on the combination and the number of input features extracted from raw signals. Sometimes, a combination of individual good features does not perform well in discriminating a class due to a high level of relevance to a second class also. Moreover, an increase in the dimensions of an input vector also degrades the performance of a classifier in most cases. To get efficient results, it is needed to input a combination of the lowest possible number of discriminating features to a classifier. In this paper, we propose a framework to improve the performance of an SVM-based classifier for sensor fault classification in two ways: firstly, by selecting the best combination of features for a target class from a feature pool and, secondly, by minimizing the dimensionality of input vectors. To obtain the best combination of features, we propose a novel feature selection algorithm that selects m out of M features having the maximum mutual information (or relevance) with a target class and the minimum mutual information with nontarget classes. This technique ensures to select the features sensitive to the target class exclusively. Furthermore, we propose a diversified-input SVM (DI-SVM) model for multiclass classification problems to achieve our second objective which is to reduce the dimensions of the input vector. In this model, the number of SVM-based classifiers is the same as the number of classes in the dataset. However, each classifier is fed with a unique combination of features selected by a feature selection scheme for a target class. The efficiency of the proposed feature selection algorithm is shown by comparing the results obtained from experiments performed with and without feature selection. Furthermore, the experimental results in terms of accuracy, receiver operating characteristics (ROC), and the area under the ROC curve (AUC-ROC) show that the proposed DI-SVM model outperforms the conventional model of SVM, the neural network, and the -nearest neighbor algorithm for sensor fault detection and classification

Deep Learning-Based Machinery Fault Diagnostics

This book offers a compilation for experts, scholars, and researchers to present the most recent advancements, from theoretical methods to the applications of sophisticated fault diagnosis techniques. The deep learning methods for analyzing and testing complex mechanical systems are of particular interest. Special attention is given to the representation and analysis of system information, operating condition monitoring, the establishment of technical standards, and scientific support of machinery fault diagnosis

Real-time Data Analytics for Condition Monitoring of Complex Industrial Systems

Modern industrial systems are now fitted with several sensors for condition monitoring. This is advantageous because these sensors can provide mass amounts of data that have the potential for aiding in tasks such as fault detection, diagnosis, and prognostics. However, the information valuable for performing these tasks is often clouded in noise and must be mined from high-dimensional data structures. Therefore, this dissertation presents a data analytics framework for performing these condition monitoring tasks using high-dimensional data. Demonstrations of this framework are detailed for challenges related to power generation systems in automobiles, power plants, and aircraft engines. These implementations leverage data collected from state-of-the-art, industry class test-rigs. Results indicate the ability of this framework to develop effective methodologies for condition monitoring of complex systems.Ph.D

Fault Prognostics Using Logical Analysis of Data and Non-Parametric Reliability Estimation Methods

RÉSUMÉ : Estimer la durée de vie utile restante (RUL) d’un système qui fonctionne suivant différentes conditions de fonctionnement représente un grand défi pour les chercheurs en maintenance conditionnelle (CBM). En effet, il est difficile de comprendre la relation entre les variables qui représentent ces conditions de fonctionnement et la RUL dans beaucoup de cas en pratique à cause du degré élevé de corrélation entre ces variables et leur dépendance dans le temps. Il est également difficile, voire impossible, pour des experts d’acquérir et accumuler un savoir à propos de systèmes complexes, où l'échec de l'ensemble du système est vu comme le résultat de l'interaction et de la concurrence entre plusieurs modes de défaillance. Cette thèse présente des méthodologies pour le pronostic en CBM basé sur l'apprentissage automatique, et une approche de découverte de connaissances appelée Logical Analysis of Data (LAD). Les méthodologies proposées se composent de plusieurs implémentations de la LAD combinées avec des méthodes non paramétriques d'estimation de fiabilité. L'objectif de ces méthodologies est de prédire la RUL du système surveillé tout en tenant compte de l'analyse des modes de défaillance uniques ou multiples. Deux d’entre elles considèrent un mode de défaillance unique et une autre considère de multiples modes de défaillance. Les deux méthodologies pour le pronostic avec mode unique diffèrent dans la manière de manipuler les données. Les méthodologies de pronostique dans cette recherche doctorale ont été testées et validées sur la base d'un ensemble de tests bien connus. Dans ces tests, les méthodologies ont été comparées à des techniques de pronostic connues; le modèle à risques proportionnels de Cox (PHM), les réseaux de neurones artificiels (ANNs) et les machines à vecteurs de support (SVMs). Deux ensembles de données ont été utilisés pour illustrer la performance des trois méthodologies: l'ensemble de données du turboréacteur à double flux (turbofan) qui est disponible au sein de la base de données pour le développement d'algorithmes de pronostic de la NASA, et un autre ensemble de données obtenu d’une véritable application dans l'industrie. Les résultats de ces comparaisons indiquent que chacune des méthodologies proposées permet de prédire avec précision la RUL du système considéré. Cette recherche doctorale conclut que l’approche utilisant la LAD possède d’importants mérites et avantages qui pourraient être bénéfiques au domaine du pronostic en CBM. Elle est capable de gérer les données en CBM qui sont corrélées et variantes dans le temps. Son autre avantage et qu’elle génère un savoir interprétable qui est bénéfique au personnel de maintenance.----------ABSTRACT : Estimating the remaining useful life (RUL) for a system working under different operating conditions represents a big challenge to the researchers in the condition-based maintenance (CBM) domain. The reason is that the relationship between the covariates that represent those operating conditions and the RUL is not fully understood in many practical cases, due to the high degree of correlation between such covariates, and their dependence on time. It is also difficult or even impossible for the experts to acquire and accumulate the knowledge from a complex system, where the failure of the system is regarded as the result of interaction and competition between several failure modes. This thesis presents systematic CBM prognostic methodologies based on a pattern-based machine learning and knowledge discovery approach called Logical Analysis of Data (LAD). The proposed methodologies comprise different implementations of the LAD approach combined with non-parametric reliability estimation methods. The objective of these methodologies is to predict the RUL of the monitored system while considering the analysis of single or multiple failure modes. Three different methodologies are presented; two deal with single failure mode and one deals with multiple failure modes. The two methodologies for single mode prognostics differ in the way of representing the data. The prognostic methodologies in this doctoral research have been tested and validated based on a set of widely known tests. In these tests, the methodologies were compared to well-known prognostic techniques; the proportional hazards model (PHM), artificial neural networks (ANNs) and support vector machines (SVMs). Two datasets were used to illustrate the performance of the three methodologies: the turbofan engine dataset that is available at NASA prognostic data repository, and another dataset collected from a real application in the industry. The results of these comparisons indicate that each of the proposed methodologies provides an accurate prediction for the RUL of the monitored system. This doctoral research concludes that the LAD approach has attractive merits and advantages that add benefits to the field of prognostics. It is capable of dealing with the CBM data that are correlated and time-varying. Another advantage is its generation of an interpretable knowledge that is beneficial to the maintenance personnel

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