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 Diagnosis Feature Space for Condition Monitoring and Fault Diagnosis of Ball Bearings

The problem of fault diagnosis and condition monitoring of ball bearings is a multidisciplinary subject. It involves research subjects from diverse disciplines of mechanical engineering, electrical engineering and in particular signal processing. In the first step, one should identify the correct method of investigation. The methods of investigation for condition monitoring of ball bearings include acoustic emission measurements, temperature monitoring, electrical current monitoring, debris analysis and vibration signal analysis. In this thesis the vibration signal analysis is employed. Once the method of analysis is selected, then features sensitive to faults should be calculated from the signal. While some of the features may be useful for condition monitoring, some of the calculated features might be extra and may not be helpful. Therefore, a feature reduction module should be employed. Initially, six features are selected as a candidate for the diagnosis feature space. After analyzing the trend of the features, it was concluded that three of the features are not appropriate for fault diagnosis. In this thesis, two problem is investigated. First the problem of identifying the effects of the fault size on the vibration signal is investigated. Also the performance of the feature space is tested in distinguishing the healthy ball bearings from the defective vibration signals

Filter-informed Spectral Graph Wavelet Networks for Multiscale Feature Extraction and Intelligent Fault Diagnosis

Intelligent fault diagnosis has been increasingly improved with the evolution of deep learning (DL) approaches. Recently, the emerging graph neural networks (GNNs) have also been introduced in the field of fault diagnosis with the goal to make better use of the inductive bias of the interdependencies between the different sensor measurements. However, there are some limitations with these GNN-based fault diagnosis methods. First, they lack the ability to realize multiscale feature extraction due to the fixed receptive field of GNNs. Secondly, they eventually encounter the over-smoothing problem with increase of model depth. Lastly, the extracted features of these GNNs are hard to understand owing to the black-box nature of GNNs. To address these issues, a filter-informed spectral graph wavelet network (SGWN) is proposed in this paper. In SGWN, the spectral graph wavelet convolutional (SGWConv) layer is established upon the spectral graph wavelet transform, which can decompose a graph signal into scaling function coefficients and spectral graph wavelet coefficients. With the help of SGWConv, SGWN is able to prevent the over-smoothing problem caused by long-range low-pass filtering, by simultaneously extracting low-pass and band-pass features. Furthermore, to speed up the computation of SGWN, the scaling kernel function and graph wavelet kernel function in SGWConv are approximated by the Chebyshev polynomials. The effectiveness of the proposed SGWN is evaluated on the collected solenoid valve dataset and aero-engine intershaft bearing dataset. The experimental results show that SGWN can outperform the comparative methods in both diagnostic accuracy and the ability to prevent over-smoothing. Moreover, its extracted features are also interpretable with domain knowledge

A Comparison of Signal Analysis Techniques for the Diagnostics of the IMS Rolling Element Bearing Dataset

In this paper, a comparison of signal analysis techniques for the diagnostics of rolling element bearings is carried out. Specifically, the comparison is performed in terms of fault detection, diagnosis and prognosis techniques with regards to the first rolling element bearing dataset released by NASA IMS Center in 2014. As for fault detection, it is obtained that RMS value, Kurtosis and Detectivity, as statistical parameters, are able to properly detect the arising of the fault on the defective bearings. Then, several signal processing techniques, such as deterministic/random signal separation, time-frequency and cyclostationary analyses are applied to perform fault diagnosis. Among these techniques, it is found that the combination of Cepstrum Pre-Whitening and Squared Envelope Spectrum, and Improved Envelope Spectrum, allow the faults to be correctly identified on specific bearing components. Finally, the Correlation, Monotonicity and Robustness of the previous statistical parameters are computed to identify the most accurate tools for bearing fault prognosis

A Robust Bearing Fault Detection and Diagnosis Technique for Brushless DC Motors Under Non-stationary Operating Conditions

Rolling element bearing defects are among the main reasons for the breakdown of electrical machines, and therefore, early diagnosis of these is necessary to avoid more catastrophic failure consequences. This paper presents a novel approach for identifying rolling element bearing defects in brushless DC motors under non-stationary operating conditions. Stator current and lateral vibration measurements are selected as fault indicators to extract meaningful features, using a discrete wavelet transform. These features are further reduced via the application of orthogonal fuzzy neighbourhood discriminative analysis. A recurrent neural network is then used to detect and classify the presence of bearing faults. The proposed system is implemented and tested in simulation on data collected from an experimental setup, to verify its effectiveness and reliability in accurately detecting and classifying the various faults

A proposal of a technique for correlating defect dimensions to vibration amplitude in bearing monitoring

The capability of early stage detection of a defect is gaining more and more importance because it can help the maintenance process, the cost reduction and the reliability of the systems. The increment of vibration amplitude is a well-known method for evaluating the damage of a component, but it is sometimes difficult to understand the exact level of damage. In other words, the amplitude of vibration cannot be directly connected to the dimension of the defect. In the present paper, based on a non-Hertzian contact algorithm, the spectrum of the pressure distribution in the contact surface between the race and the rolling element is evaluated. Such spectrum is then compared with the acquired spectrum of a vibration response of a defected bearing. The bearing vibration pattern was previously analyzed with monitoring techniques to extract all the damage information. The correlation between the spectrum of the pressure distribution in the defected contact surface and the analyzed spectrum of the damaged bearing highlights a strict relationship. By using that analysis, a precise correlation between defect aspect and dimension and vibration level can be addressed to estimate the level of damaging

Knowledge-based fault detection using time-frequency analysis

This work studies a fault detection method which analyzes sensor data for changes in their characteristics to detect the occurrence of faults in a dynamic system. The test system considered in this research is a Boeing-747 aircraft system and the faults considered are the actuator faults in the aircraft. The method is an alternative to conventional fault detection method and does not rely on analytical mathematical models but acquires knowledge about the system through experiments. In this work, we test the concept that the energy distribution of resolution than the windowed Fourier transform. Verification of the proposed methodology is carried in two parts. The first set of experiments considers entire data as a single window. Results show that the method effectively classifies the indicators by more that 85% as correct detections. The second set of experiments verifies the method for online fault detection. It is observed that the mean detection delay was less than 8 seconds. We also developed a simple graphical user interface to run the online fault detection

online condition monitoring of bearings for improved reliability in packaging materials industry

The production processes in the packaging materials industry has to be very efficient and cost-effective. These processes usually take place under extreme conditions and high speeds that requires a high level of reliability and efficiency. Rollers including their supporting bearings and motors are the most common components of production machines in the packaging materials industry. Bearing faults, which often occur gradually, represent one of the foremost causes of failures in the industry. Therefore it is very important to take care of bearings during maintenance and detect their faults in an early stage in order to assure safe and efficient operation. We present a new automated technique for early fault detection and diagnosis in rolling-element bearings based on vibration signal analysis. After normalization and the wavelet transform of vibration signals, the standard deviation as a measure of average energy level and the logarithmic energy entropy as a measure of the degree of order/disorder are extracted in a few sub-bands of interest as representative features. Then the feature space dimension is optimally reduced to two using scatter matrices. In the reduced two-dimensional feature space the fault detection is performed by a quadratic classifier and the fault diagnosis by another two quadratic classifiers. Accuracy of the new technique was tested on the ball bearing data recorded at the Case Western Reserve University Bearing Data Center. In total four classes of the vibrations signals were studied, i.e. normal, with the fault of inner race, outer race and balls operation. An overall accuracy of 100% was achieved. The new technique can be used to increase reliability and efficiency by preventing unexpected faulty operation of machinery bearings