Industrial data-driven monitoring based on incremental learning applied to the detection of novel faults

The detection of uncharacterized events during electromechanical systems operation represents one of the most critical data challenges dealing with condition-based monitoring under the Industry 4.0 framework. Thus, the detection of novelty conditions and the learning of new patterns are considered as mandatory competencies in modern industrial applications. In this regard, this article proposes a novel multifault detection and identification scheme, based on machine learning, information data-fusion, novelty-detection, and incremental learning. First, statistical time-domain features estimated from multiple physical magnitudes acquired from the electrical motor under inspection are fused under a feature-fusion level scheme. Second, a self-organizing map structure is proposed to construct a data-based model of the available conditions of operation. Third, the incremental learning of the condition-based monitoring scheme is performed adding self-organizing structures and optimizing their projections through a linear discriminant analysis. The performance of the proposed scheme is validated under a complete set of experimental scenarios from two different cases of study, and the results compared with a classical approach.Peer ReviewedPostprint (author's final draft

Multimodal forecasting methodology applied to industrial process monitoring

IEEE Industrial process modelling represents a key factor to allow the future generation of industrial manufacturing plants. In this regard, accurate models of critical signals need to be designed in order to forecast process deviations. In this work a novel multimodal forecasting methodology based on adaptive dynamics packaging and codification of the process operation is proposed. First, a target signal is decomposed by means of the Empirical Mode Decomposition in order to identify the characteristics intrinsic mode functions. Second, such dynamics are packaged depending on their significance and modelling complexity. Third, the operating condition of the considered process, reflected by available auxiliary signals, is codified by means of a Self-Organizing Map and presented to the modelling structure. The forecasting structure is supported by a set of ensemble ANFIS based models, each one focused on a different set of signal dynamics. The performance and effectiveness of the proposed method is validated experimentally with industrial data from a copper rod manufacturing plant and performance comparison with classical approaches. The proposed method improves performance and generalization versus classical single model approaches.Peer ReviewedPostprint (author's final draft

Sensitivity analysis of sensors in a hydraulic condition monitoring system using CNN models

Condition monitoring (CM) is a useful application in industry 4.0, where the machine’s health is controlled by computational intelligence methods. Data-driven models, especially from the field of deep learning, are efficient solutions for the analysis of time series sensor data due to their ability to recognize patterns in high dimensional data and to track the temporal evolution of the signal. Despite the excellent performance of deep learning models in many applications, additional requirements regarding the interpretability of machine learning models are getting relevant. In this work, we present a study on the sensitivity of sensors in a deep learning based CM system providing high-level information about the relevance of the sensors. Several convolutional neural networks (CNN) have been constructed from a multisensory dataset for the prediction of different degradation states in a hydraulic system. An attribution analysis of the input features provided insights about the contribution of each sensor in the prediction of the classifier. Relevant sensors were identified, and CNN models built on the selected sensors resulted equal in prediction quality to the original models. The information about the relevance of sensors is useful for the system’s design to decide timely on the required sensorsPeer ReviewedPostprint (published version

Three-stage Hybrid Fault Diagnosis for Rolling Bearings with Compressively-sampled data and Subspace Learning Techniques

To avoid the burden of much storage requirements and processing time, this paper proposes a three-stage hybrid method, Compressive Sampling with Correlated Principal and Discriminant Components (CSCPDC), for bearing faults diagnosis based on compressed measurements. In the first stage, Compressive Sampling (CS) is utilised to obtain compressively-sampled signals from raw vibration data. In the second stage, an effective multi-step feature learning algorithm obtains fewer features from correlated principal and discriminant attributes from the compressively-sampled signals, which are then concatenated to increase the performance. In the third stage, with these concatenated features, Multi-class Support Vector Machine (SVM) is used to train, validate, and classify bearing faults. Results show that the proposed method, CS-CPDC, offers high classification accuracies, reduced computation time, and storage requirement, with fewer measurements.National Science Foundation of China; National Science Foundation of Shanghai

Compressive Sampling and Feature Ranking Framework for Bearing Fault Classification with Vibration Signals

Failures of rolling element bearings are amongst the main causes of machines breakdowns. To prevent such breakdowns, bearing health monitoring is performed by collecting data from rotating machines, extracting features from the collected data, and applying a classifier to classify faults. To avoid the burden of much storage requirements and processing time of a tremendously large amount of vibration data, the present paper proposes a combined Compressive Sampling (CS) based on Multiple Measurement Vector (MMV) and Feature Ranking (FR) framework to learn optimally fewer features from a large amount of vibration data from which bearing health conditions can be classified. The CS-based on MMV model is the first step in this framework and provides compressively-sampled signals based on compressed sampling rates. In the second step, the search for the most important features of these compressively-sampled signals is performed using feature ranking and selection techniques. For that purpose, we have investigated the following: (1) two compressible representations of vibration signals that can be used within CS framework, namely, Fast Fourier Transform (FFT) based coefficients and thresholded Wavelet Transform (WT) based coefficients, and (2) several feature ranking and selection techniques, namely, three similarity-based techniques, Fisher Score (FS), Laplacian Score (LS), Relief-F; one correlation-based technique, Pearson Correlation Coefficients (PCC); and one independence test technique, Chi-Square (Chi-2) to select fewer features that can sufficiently represent the original vibration signals. These selected features, in combination with three of the popular classifiers - multinomial Logistic Regression classifier (LRC), Artificial Neural Networks (ANNs), and Support Vector Machines (SVMs), have been evaluated for the classification of bearing faults. Results show that the proposed framework achieves high classification accuracies with a limited amount of data using various combinations of methods, which outperform recently published results