Incipient fault diagnosis of roller bearing using optimized wavelet transform based multi-speed vibration signatures

Condition monitoring and incipient fault diagnosis of rolling bearing is of great importance to detect failures and ensure reliable operations in rotating machinery. In this paper, a new multi-speed fault diagnostic approach is presented by using self-adaptive wavelet transform components generated from bearing vibration signals. The proposed approach is capable of discriminating signatures from four conditions of rolling bearing, i.e. normal bearing and three different types of defected bearings on outer race, inner race and roller separately. Particle Swarm Optimization (PSO) and Broyden-Fletcher-Goldfarb-Shanno (BFGS) based quasi-Newton minimization algorithms are applied to seek optimal parameters of Impulse Modelling based Continuous Wavelet Transform (IMCWT) model. Then, a three-dimensional feature space of the statistical parameters and a Nearest Neighbor (NN) classifier are respectively applied for fault signature extraction and fault classification. Effectiveness of this approach is then evaluated, and the results have achieved an overall accuracy of 100%. Moreover, the generated discriminatory fault signatures are suitable for multi-speed fault data sets. This technique will be further implemented and tested in a real industrial environment

A multi-fault diagnosis method for piston pump in construction machinery based on information fusion and PSO-SVM

Piston pumps are key components in construction machinery, the failure of which may cause long delay of the construction work and even lead to serious accident. Because construction machines are exposed to poor working conditions, multiple faults of piston pumps are most likely to occur simultaneously. When multiple faults occur together, it is difficult to detect. A multi-fault diagnosis method for piston pump based on information fusion and PSO-SVM is proposed in this thesis. Information fusion is used as fault feature extraction and PSO-SVM is applied as the fault mode classifier. According to the method, vibration signal and pressure signal of piston pump in normal state, single fault state and multi-fault state are collected at first. Then the empirical mode decomposition (EMD) is used to decompose vibration signals into different frequency band and energy features are extracted. These energy features extracted from vibration signals and time-domain features extracted from pressure signal are information fused at the feature layer and constitute the eigenvectors. Finally, these eigenvectors are put into support vector machine (SVM) and the working conditions of piston pump were classified. Particle swarm optimization (PSO) is applied to optimize two parameters of SVM. The experimental results show that the recognition accuracy of the normal state, three single failure modes and multi-fault modes are 98.3 %, 97.6 % and 94 % respectively. These recognition accuracies are higher than which using vibration signal or pressure signal alone. So, the proposed method can not only identify the single fault, but also effectively identify the multi-fault of piston pump

Fault Diagnosis and Failure Prognostics of Lithium-ion Battery based on Least Squares Support Vector Machine and Memory Particle Filter Framework

123456A novel data driven approach is developed for fault diagnosis and remaining useful life (RUL) prognostics for lithium-ion batteries using Least Square Support Vector Machine (LS-SVM) and Memory-Particle Filter (M-PF). Unlike traditional data-driven models for capacity fault diagnosis and failure prognosis, which require multidimensional physical characteristics, the proposed algorithm uses only two variables: Energy Efficiency (EE), and Work Temperature. The aim of this novel framework is to improve the accuracy of incipient and abrupt faults diagnosis and failure prognosis. First, the LSSVM is used to generate residual signal based on capacity fade trends of the Li-ion batteries. Second, adaptive threshold model is developed based on several factors including input, output model error, disturbance, and drift parameter. The adaptive threshold is used to tackle the shortcoming of a fixed threshold. Third, the M-PF is proposed as the new method for failure prognostic to determine Remaining Useful Life (RUL). The M-PF is based on the assumption of the availability of real-time observation and historical data, where the historical failure data can be used instead of the physical failure model within the particle filter. The feasibility of the framework is validated using Li-ion battery prognostic data obtained from the National Aeronautic and Space Administration (NASA) Ames Prognostic Center of Excellence (PCoE). The experimental results show the following: (1) fewer data dimensions for the input data are required compared to traditional empirical models; (2) the proposed diagnostic approach provides an effective way of diagnosing Li-ion battery fault; (3) the proposed prognostic approach can predict the RUL of Li-ion batteries with small error, and has high prediction accuracy; and, (4) the proposed prognostic approach shows that historical failure data can be used instead of a physical failure model in the particle filter

Improving the weak feature extraction by adaptive stochastic resonance in cascaded piecewise-linear system and its application in bearing fault detection

In mechanical engineering field, early fault features are extremely weak and submerged in heavy noise, and the weak feature extraction is quite challenging. In this work, we apply the adaptive stochastic resonance in cascaded piecewise-linear system to extract the weak features. The adaptive stochastic resonance is realized by the quantum particle swarm algorithm. By optimizing system parameters, the efficiency of the feature extraction is improved greatly. As a result, the weak features can be easily extracted eventually. The effectiveness and the high-performance of the proposed method are verified by the numerical simulation and experimental data of rolling element bearings. The bearing fault under different motor loads is detected effectively, consequently confirming the robustness of the proposed method

Fault diagnosis of rope tension in hoisting systems based on vibration signals

Fault diagnosis of rope tension is of great significance for safety in hoisting systems. A novel diagnosis method based on the vibration signals of the head sheaves is proposed. First, the signal is decomposed by the ensemble empirical mode decomposition (EEMD); then the main intrinsic module functions (IMFs) are extracted by correlation analysis. Second, the energy and the permutation entropy (PE) of the main IMFs were calculated to create the feature vector. Third, a particle swarm optimization - support vector machine (PSO-SVM) is applied to classify tension states. The effectiveness and advantage of the proposed method are validated by experiments. Compared with the conventional force-sensor-based method, it has clear advantages in sensor installation, data transmission, safety, and reliability

Variational mode decomposition: mode determination method for rotating machinery diagnosis

Variational mode decomposition (VMD) is a modern decomposition method used for many engineering monitoring and diagnosis recently, which replaced traditional empirical mode decomposition (EMD) method. However, the performance of VMD method specifically depends on the parameter that need to pre-determine for VMD method especially the mode number. This paper proposed a mode determination method using signal difference average (SDA) to determine the mode number for the VMD method by taking the advantages of similarities concept between sum of variational mode functions (VMFs) and the input signals. Online high-speed gear and bearing fault data were used to validate the performance of the proposed method. The diagnosis result using frequency spectrum has been compared with traditional EMD method and the proposed method has been proved to be able to provide an accurate number of mode for the VMD method effectively for rotating machinery applications

Comparison of Metaheuristic Optimization Algorithms for Electromechanical Actuator Fault Detection

Model-based Fault Detection and Identification (FDI) for prognostics rely on the comparison between the response of the monitored system and that of a digital twin. Discrepancies among the behavior of the two systems are analyzed to filter out the effect of uncertainties of the model and identify failure precursors. A possible solution to identify faults is to leverage a model able to simulate faults: an optimization algorithm varies the faults magnitude parameters within the model to achieve the matching between the responses of the model and the actual system. When the algorithm converges, we can assume that the fault parameters that produce the best match between the system and its digital twin approximate the actual faults affecting the equipment. The choice of an optimization algorithm appropriate for the task is highly problem dependent. Algorithms for FDI are required to deal with multimodal objective functions characterized by poor regularity and a relatively high computational cost. Additionally, the derivatives of the objective function are not usually available and must be obtained numerically if needed. Then, we restrict our search for a suitable optimization algorithm to metaheuristic gradient-free ones, testing Genetic Algorithm, Particle Swarm Optimization, Differential Evolution, Grey Wolf Optimization, Dragonfly Algorithm, and Whale Optimization Algorithm. Their performances on the considered problem were assessed and compared, in terms of accuracy and computational time

Adaptive Multiscale Weighted Permutation Entropy for Rolling Bearing Fault Diagnosis

© 2020 The Author(s). This work is licensed under a Creative Commons Attribution 4.0 License. For more information, see https://creativecommons.org/licenses/by/4.0/.Bearing vibration signals contain non-linear and non-stationary features due to instantaneous variations in the operation of rotating machinery. It is important to characterize and analyze the complexity change of the bearing vibration signals so that bearing health conditions can be accurately identified. Entropy measures are non-linear indicators that are applicable to the time series complexity analysis for machine fault diagnosis. In this paper, an improved entropy measure, termed Adaptive Multiscale Weighted Permutation Entropy (AMWPE), is proposed. Then, a new rolling bearing fault diagnosis method is developed based on the AMWPE and multi-class SVM. For comparison, experimental bearing data are analyzed using the AMWPE, compared with the conventional entropy measures, where a multi-class SVM is adopted for fault type classification. Moreover, the robustness of different entropy measures is further studied for the analysis of noisy signals with various Signal-to-Noise Ratios (SNRs). The experimental results have demonstrated the effectiveness of the proposed method in fault diagnosis of rolling bearing under different fault types, severity degrees, and SNR levels.Peer reviewedFinal Accepted Versio

Research on intelligent fault diagnosis of mechanical equipment based on sparse deep neural networks

In the big data background, the accuracy of fault diagnosis and recognition has been difficult to be improved. The deep neural network was used to recognize the diagnosis rate of the bearing with four kinds of conditions and compared with traditional BP neural network, genetic neural network and particle swarm neural network. Results showed that the diagnosis accuracy and convergence rate of the deep neural network were obviously higher than those of other models. Fault diagnosis rates with different sample sizes and training sample proportions were then studied to compare with the latest reported methods. Results showed that fault diagnosis had a good stability using deep neural networks. Vibration accelerations of the bearing with different fault diameters and excitation loads were extracted. The deep neural network was used to recognize these faults. Diagnosis accuracy was very high. In particular, the fault diagnosis rate was 98 % when signal features of vibration accelerations were very obvious, which indicated that using deep neural network was effective in diagnosing and recognizing different types of faults. Finally, the deep neural network was used to conduct fault diagnosis for the gearbox of wind turbines and compared with the other models to present that it would work well in the industrial environment