Approach for Improved Signal-Based Fault Diagnosis of Hot Rolling Mills

Der hier vorgestellte Ansatz ist in der Lage, zwei spezifische schwere Fehler zu erkennen, sie zu identifizieren, zwischen vier verschiedenen Systemzuständen zu unterscheiden und eine Prognose bezüglich des Systemverhaltens zu geben. Die vorliegende Arbeit untersucht die Zustandsüberwachung des komplexen Herstellungsprozesses eines Warmbandwalzwerks. Eine signalbasierte Fehlerdiagnose und ein Fehlerprognoseansatz für den Bandlauf werden entwickelt. Eine Literaturübersicht gibt einen Überblick über die bisherige Forschung zu verwandten Themen. Es wird gezeigt, dass die große Anzahl vorheriger Arbeiten diese Thematik nicht gelöst hat und dass weitere Untersuchungen erforderlich sind, um eine zufriedenstellende Lösung der behandelten Probleme zu erhalten. Die Entwicklung einer neuen Signalverarbeitungskette und die Signalverarbeitungsschritte sind detailliert dargestellt. Die Klassifikationsaufgabe wird in Fehlerdiagnose, Fehleridentifikation und Fehlerprognose differenziert. Der vorgeschlagene Ansatz kombiniert fünf verschiedene Methoden zur Merkmalsextraktion, nämlich Short-Time Fourier Transformation, kontinuierliche Wavelet Transformation, diskrete Wavelet Transformation, Wigner-Ville Distribution und Empirical Mode Decomposition, mit zwei verschiedenen Klassifikationsalgorithmen, nämlich Support-Vektor Maschine und eine Variation der Kreuzkorrelation, wobei letztere in dieser Arbeit entwickelt wurde. Kombinationen dieser Merkmalsextraktion und Klassifikationsverfahren werden an Walzkraft-Daten aus einer Warmbreitbandstraße angewendet.The approach introduced here is able to detect two specific severe faults, to identify them, to distinguish between four different system states, and to give a prognosis on the system behavior. The presented work investigates the condition monitoring of the complex production process of a hot strip rolling mill. A signal-based fault diagnosis and fault prognosis approach for strip travel is developed. A literature review gives an overview about previous research on related topics. It is shown that the great amount of previous work does not cope with the problems treated in this work and that further investigation is necessary to provide a satisfactory solution. The design of a new signal processing chain is presented and the signal processing steps are detailed. The classification task is differentiated into fault detection, fault identification and fault prognosis. The proposed approach combines five different methods for feature extraction, namely short time Fourier transform, continuous wavelet transform, discrete wavelet transform, Wigner-Ville distribution, and empirical mode decomposition, with two different classification algorithms, namely support vector machine and a variation of cross-correlation, the latter developed in this work. Combinations of these feature extraction and classification methods are applied to rolling force data originating from a hot strip mill

30th International Conference on Condition Monitoring and Diagnostic Engineering Management (COMADEM 2017)

Proceedings of COMADEM 201

Hilbert-Huang Transformによる薄肉加工物の機械加工における振動の解析

広島大学(Hiroshima University)博士(工学)Doctor of Engineeringdoctora

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

On-line learning and anomaly detection methods : applications to fault assessment

[Abstract] This work lays at the intersection of two disciplines, Machine Learning (ML) research and predictive maintenance of machinery. On the one hand, Machine Learning aims at detecting patterns in data gathered from phenomena which can be very different in nature. On the other hand, predictive maintenance of industrial machinery is the discipline which, based on the measurement of physical conditions of its internal components, assesses its present and near future condition in order to prevent fatal failures. In this work it is highlighted that these two disciplines can benefit from their synergy. Predictive maintenance is a challenge for Machine Learning algorithms due to the nature of data generated by rotating machinery: (a) each machine constitutes an new individual case so fault data is not available for model construction and (b) working conditions of the machine are changeable in many situations and affects captured data. Machine Learning can help predictive maintenance to: (a) cut plant costs though the automation of tedious periodic tasks which are carried out by experts and (b) reduce the probability of fatal damages in machinery due to the possibility of monitoring it more frequently at a modest cost increase. General purpose ML techniques able to deal with the aforementioned conditions are proposed. Also, its application to the specific field of predictive maintenance of rotating machinery based on vibration signature analysis is thoroughly treated. Since only normal state data is available to model the vibration captures of a machine, we are restricted to the use of anomaly detection algorithms, which will be one of the main blocks of this work. In addition, predictive maintenance also aims at assessing its state in the near future. The second main block of this work, on-line learning algorithms, will help us in this task. A novel on-line learning algorithm for a single layer neural network with a non-linear output function is proposed. In addition to the application to predictive maintenance, the proposed algorithm is able to continuously train a network in a one pattern at a time manner. If some conditions are hold, it analytically ensures to reach a global optimal model. As well as predictive maintenance, the proposed on-line learning algorithm can be applied to scenarios of stream data learning such as big data sets, changing contexts and distributed data. Some of the principles described in this work were introduced in a commercial software prototype, GIDASR ? . This software was developed and installed in real plants as part of the work of this thesis. The experiences in applying ML to fault detection with this software are also described and prove that the proposed methodology can be very effective. Fault detection experiments with simulated and real vibration data are also carried out and demonstrate the performance of the proposed techniques when applied to the problem of predictive maintenance of rotating machinery.[Resumen] La presente tesis doctoral se sitúa en el ámbito de dos disciplinas, la investigación en Aprendizaje Computacional (AC) y el Mantenimiento Predictivo (MP) de maquinaria rotativa. Por una parte, el AC estudia la problemática de detectar y clasificar patrones en conjuntos de datos extraídos de fenómenos de interés de la más variada naturaleza. Por su parte, el MP es la disciplina que, basándose en la monitorización de variables físicas de los componentes internos de maquinaria industrial, se encarga de valorar las condiciones de éstos tanto en el momento presente como en un futuro próximo con el fin último de prevenir roturas que pueden resultar de fatales consecuencias. En este trabajo se pone de relevancia que ambas disciplinas pueden beneficiarse de su sinergia. El MP supone un reto para el AC debido a la naturaleza de los datos generados por la maquinaria: (a) las propiedades de las medidas físicas recogidas varían para cada máquina y, debido a que la monitorización debe comenzar en condiciones correctas, no contamos con datos de fallos para construir un modelo de comportamiento y (b) las condiciones de funcionamiento de las máquinas pueden ser variables y afectar a los datos generados por éstas. El AC puede ayudar al MP a: (a) reducir costes a través de la automatización de tareas periódicas tediosas que tienen que ser realizadas por expertos en el área y (b) reducir la probabilidad de grandes da˜nos a la maquinaria gracias a la posibilidad de monitorizarla con una mayor frecuencia sin elevar los costes sustancialmente. En este trabajo, se proponen algoritmos de AC de propósito general capaces de trabajar en las condiciones anteriores. Además, su aplicación específica al campo del mantenimiento predictivo de maquinaria rotativa basada en el análisis de vibraciones se estudia en detalle, aportando resultados para casos reales. El hecho de disponer sólamente de datos en condiciones de normalidad de la maquinaria nos restringe al uso de técnicas de detección de anomalías. éste será uno de los bloques principales del presente trabajo. Por otra parte, el MP también intenta valorar si la maquinaria se encontrará en un estado inaceptable en un futuro próximo. En el segundo bloque se presenta un nuevo algoritmo de aprendizaje en tiempo real (on-line) que será de gran ayuda en esta tarea. Se propone un nuevo algoritmo de aprendizaje on-line para una red neuronas monocapa con función de transferencia no lineal. Además de su aplicación al mantenimiento predictivo, el algoritmo propuesto puede ser empleado en otros escenarios de aprendizaje on-line como grandes conjuntos de datos, cambios de contexto o datos distribuidos. Algunas de las ideas descritas en este trabajo fueron implantadas en un prototipo de software comercial, GIDASR ? . Este software fue desarrollado e implantado en plantas reales por el autor de este trabajo y las experiencias extraídas de su aplicación también se describen en el presente volumen[Resumo] O presente traballo sitúase no ámbito de dúas disciplinas, a investigación en Aprendizaxe Computacional (AC) e o Mantemento Predictivo (MP) de maquinaria rotativa. Por unha banda, o AC estuda a problemática de detectar e clasificar patróns en conxuntos de datos extraídos de fenómenos de interese da máis variada natureza. Pola súa banda, o MP é a disciplina que, baseándose na monitorización de variables físicas dos seus compo˜nentes internos, encárgase de valorar as condicións destes tanto no momento presente como nun futuro próximo co fin último de previr roturas que poden resultar de fatais consecuencias. Neste traballo ponse de relevancia que ambas disciplinas poden beneficiarse da súa sinergia. O MP supón un reto para o AC debido á natureza dos datos xerados pola maquinaria: (a) as propiedades das medidas físicas recolleitas varían para cada máquina e, debido a que a monitorización debe comezar en condicións correctas, non contamos con datos de fallos para construír un modelo de comportamento e (b) as condicións de funcionamento das máquinas poden ser variables e afectar aos datos xerados por estas. O AC pode axudar ao MP a: (a) reducir custos a través da automatización de tarefas periódicas tediosas que te˜nen que ser realizadas por expertos no área e (b) reducir a probabilidade de grandes danos na maquinaria grazas á posibilidade de monitorizala cunha maior frecuencia sen elevar os custos sustancialmente. Neste traballo, propó˜nense algoritmos de AC de propósito xeral capaces de traballar nas condicións anteriores. Ademais, a súa aplicación específica ao campo do mantemento predictivo de maquinaria rotativa baseada na análise de vibracións estúdase en detalle aportando resultados para casos reais. Debido a contar só con datos en condicións de normalidade da maquinaria, estamos restrinxidos ao uso de técnicas de detección de anomalías. éste será un dos bloques principais do presente traballo. Por outra banda, o MP tamén intenta valorar si a maquinaria atoparase nun estado inaceptable nun futuro próximo. No segundo bloque do presente traballo preséntase un novo algoritmo de aprendizaxe en tempo real (on-line) que será de gran axuda nesta tarefa. Proponse un novo algoritmo de aprendizaxe on-line para unha rede neuronas monocapa con función de transferencia non lineal. Ademais da súa aplicación ao mantemento predictivo, o algoritmo proposto pode ser empregado en escenarios de aprendizaxe on-line como grandes conxuntos de datos, cambios de contexto ou datos distribuídos. Algunhas das ideas descritas neste traballo foron implantadas nun prototipo de software comercial, GIDASR ? . Este software foi desenvolvido e implantado en plantas reais polo autor deste traballo e as experiencias extraídas da súa aplicación tamén se describen no presente volume

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

Advances in Condition Monitoring, Optimization and Control for Complex Industrial Processes

The book documents 25 papers collected from the Special Issue “Advances in Condition Monitoring, Optimization and Control for Complex Industrial Processes”, highlighting recent research trends in complex industrial processes. The book aims to stimulate the research field and be of benefit to readers from both academic institutes and industrial sectors

Utilizing the mechanical redundancy of parallel systems for condition monitoring hydraulic pumps in variable operation

This work investigates and develops an approach to resolve some of the unique challenges associated with condition monitoring variable duty equipment. The proposed solution utilizes the mechanical redundancy of parallel systems to create dynamic criterion for detecting incipient faults. In this context, parallel systems are those which contain multiple subsystems (with similar construction) having synchronized operating conditions. This work evaluates the proposed methodology through its application on parallel hydraulic gear pumps. By comparing the dynamic pressure and vibration signal features, it was found that this approach is capable of distinguishing various incipient failures while the pumps were in both stationary and non-stationary operation.Masters of Applied Science (MASc) in Natural Resources Engineerin