Incremental learning framework-based condition monitoring for novelty fault identification applied to electromechanical systems

A great deal of investigations are being carried out towards the effective implementation of the 4.0 Industry new paradigm. Indeed, most of the machinery involved in industrial processes are intended to be digitalized aiming to obtain enhanced information to be used for an optimized operation of the whole manufacturing process. In this regard, condition monitoring strategies are being also reconsidered to include improved performances and functionalities. Thus, the contribution of this research work lies in the proposal of an incremental learning framework approach applied to the condition monitoring of electromechanical systems. The proposed strategy is divided in three main steps, first, different available physical magnitudes are characterized through the calculation of a set of statistical-time based features. Second, a modelling of the considered conditions is performed by means of self-organizing maps in order to preserve the topology of the data; and finally, a novelty detection is carried out by a comparison among the quantization error value achieved in the data modelling for each of the considered conditions. The effectiveness of the proposed novelty fault identification condition monitoring methodology is proved by means of the evaluation of a complete experimental database acquired during the continuous working conditions of an electromechanical system. © 2018 IEEE.Peer ReviewedPostprint (author's final draft

A survey of outlier detection methodologies

Outlier detection has been used for centuries to detect and, where appropriate, remove anomalous observations from data. Outliers arise due to mechanical faults, changes in system behaviour, fraudulent behaviour, human error, instrument error or simply through natural deviations in populations. Their detection can identify system faults and fraud before they escalate with potentially catastrophic consequences. It can identify errors and remove their contaminating effect on the data set and as such to purify the data for processing. The original outlier detection methods were arbitrary but now, principled and systematic techniques are used, drawn from the full gamut of Computer Science and Statistics. In this paper, we introduce a survey of contemporary techniques for outlier detection. We identify their respective motivations and distinguish their advantages and disadvantages in a comparative review

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

Smart Monitoring Based on Novelty Detection and Artificial Intelligence Applied to the Condition Assessment of Rotating Machinery in the Industry 4.0

The application of condition monitoring strategies for detecting and assessing unexpected events during the operation of rotating machines is still nowadays the most important equipment used in industrial processes; thus, their appropriate working condition must be ensured, aiming to avoid unexpected breakdowns that could represent important economical loses. In this regard, smart monitoring approaches are currently playing an important role for the condition assessment of industrial machinery. Hence, in this work an application is presented based on a novelty detection approach and artificial intelligence techniques for monitoring and assessing the working condition of gearbox-based machinery used in processes of the Industry 4.0. The main contribution of this work lies in modeling the normal working condition of such gearbox-based industrial process and then identifying the occurrence of faulty conditions under a novelty detection framework

Damage identification in structural health monitoring: a brief review from its implementation to the Use of data-driven applications

The damage identification process provides relevant information about the current state of a structure under inspection, and it can be approached from two different points of view. The first approach uses data-driven algorithms, which are usually associated with the collection of data using sensors. Data are subsequently processed and analyzed. The second approach uses models to analyze information about the structure. In the latter case, the overall performance of the approach is associated with the accuracy of the model and the information that is used to define it. Although both approaches are widely used, data-driven algorithms are preferred in most cases because they afford the ability to analyze data acquired from sensors and to provide a real-time solution for decision making; however, these approaches involve high-performance processors due to the high computational cost. As a contribution to the researchers working with data-driven algorithms and applications, this work presents a brief review of data-driven algorithms for damage identification in structural health-monitoring applications. This review covers damage detection, localization, classification, extension, and prognosis, as well as the development of smart structures. The literature is systematically reviewed according to the natural steps of a structural health-monitoring system. This review also includes information on the types of sensors used as well as on the development of data-driven algorithms for damage identification.Peer ReviewedPostprint (published version

Induction Machine Stator Fault Tracking using the Growing Curvilinear Component Analysis

Detection of stator-based faults in Induction Machines (IMs) can be carried out in numerous ways. In particular, the shorted turns in stator windings of IM are among the most common faults in the industry. As a matter of fact, most IMs come with pre-installed current sensors for the purpose of control and protection. At this aim, using only the stator current for fault detection has become a recent trend nowadays as it is much cheaper than installing additional sensors. The three-phase stator current signatures have been used in this study to observe the effect of stator inter-turn fault with respect to the healthy condition of the IM. The pre-processing of the healthy and faulty current signatures has been done via the in-built DSP module of dSPACE after which, these current signatures are passed into the MATLAB® software for further analysis using AI techniques. The authors present a Growing Curvilinear Component Analysis (GCCA) neural network that is capable of detecting and follow the evolution of the stator fault using the stator current signature, making online fault detection possible. For this purpose, a topological manifold analysis is carried out to study the fault evolution, which is a fundamental step for calibrating the GCCA neural network. The effectiveness of the proposed method has been verified experimentally

Disentangled Causal Graph Learning forOnline Unsupervised Root Cause Analysis

The task of root cause analysis (RCA) is to identify the root causes of system faults/failures by analyzing system monitoring data. Efficient RCA can greatly accelerate system failure recovery and mitigate system damages or financial losses. However, previous research has mostly focused on developing offline RCA algorithms, which often require manually initiating the RCA process, a significant amount of time and data to train a robust model, and then being retrained from scratch for a new system fault. In this paper, we propose CORAL, a novel online RCA framework that can automatically trigger the RCA process and incrementally update the RCA model. CORAL consists of Trigger Point Detection, Incremental Disentangled Causal Graph Learning, and Network Propagation-based Root Cause Localization. The Trigger Point Detection component aims to detect system state transitions automatically and in near-real-time. To achieve this, we develop an online trigger point detection approach based on multivariate singular spectrum analysis and cumulative sum statistics. To efficiently update the RCA model, we propose an incremental disentangled causal graph learning approach to decouple the state-invariant and state-dependent information. After that, CORAL applies a random walk with restarts to the updated causal graph to accurately identify root causes. The online RCA process terminates when the causal graph and the generated root cause list converge. Extensive experiments on three real-world datasets with case studies demonstrate the effectiveness and superiority of the proposed framework