Computing Intelligence Technique and Multiresolution Data Processing for Condition Monitoring

Condition monitoring (CM) of rotary machines has gained increasing importance and extensive research in recent years. Due to the rapid growth of data volume, automated data processing is necessary in order to deal with massive data efficiently to produce timely and accurate diagnostic results. Artificial intelligence (AI) and adaptive data processing approaches can be promising solutions to the challenge of large data volume. Unfortunately, the majority of AI-based techniques in CM have been developed for only the post-processing (classification) stage, whereas the critical tasks including feature extraction and selection are still manually processed, which often require considerable time and efforts but also yield a performance depending on prior knowledge and diagnostic expertise. To achieve an automatic data processing, the research of this PhD project provides an integrated framework with two main approaches. Firstly, it focuses on extending AI techniques in all phases, including feature extraction by applying Componential Coding Neural Network (CCNN) which has been found to have unique properties of being trained through unsupervised learning, capable of dealing with raw datasets, translation invariance and high computational efficiency. These advantages of CCNN make it particularly suitable for automated analyzing of the vibration data arisen from typical machine components such as the rolling element bearings which exhibit periodic phenomena with high non-stationary and strong noise contamination. Then, once an anomaly is detected, a further analysis technique to identify the fault is proposed using a multiresolution data analysis approach based on Double-Density Discrete Wavelet Transform (DD-DWT) which was grounded on over-sampled filter banks with smooth tight frames. This makes it nearly shift-invariant which is important for extracting non-stationary periodical peaks. Also, in order to denoise and enhance the diagnostic features, a novel level-dependant adaptive thresholding method based on harmonic to signal ratio (HSR) is developed and implemented on the selected wavelet coefficients. This method has been developed to be a semi-automated (adaptive) approach to facilitate the process of fault diagnosis. The developed framework has been evaluated using both simulated and measured datasets from typical healthy and defective tapered roller bearings which are critical parts of all rotating machines. The results have demonstrated that the CCNN is a robust technique for early fault detection, and also showed that adaptive DD-DWT is a robust technique for diagnosing the faults induced to test bearings. The developed framework has achieved multi-objectives of high detection sensitivity, reliable diagnosis and minimized computing complexity

Extraction of Information from Vibration Data using Double Density Discrete Wavelet Analysis for Condition Monitoring

Many condition monitoring (CM) techniques have been investigated for the purpose of early fault detection and diagnosis in order to avoid unexpected machine breakdowns. However, non-stationary and non-linear characteristics of vibration data can make the signal analysis a challenging task. Multiresolution data analysis approaches have received significant attention in recent years and are widely applied to analyse non-stationary and non-linear data. Double-Density Discrete Wavelet Transform (DD-DWT), which was originally developed for image processing, is proposed and investigated in this paper for effectively extracting diagnostic features from the vibration measurements. DD-DWT has the merits of nearly shift-invariant and less frequency aliasing which and allows the effective extraction of non-stationary periodic peaks, compared with the undecimated DWT. Techniques based on thresholding of wavelet coefficients are gaining popularity for denoising data. The implementation of global, level-dependent, and subband-dependent thresholding based methods are investigated and implemented on the selected wavelet coefficients in order to denoise and enhance the periodic and impulsive fault features. The performance of the proposed method has been evaluated against DWT using both simulated data and experimental datasets from defective tapered roller bearings. Results, using the harmonic to signal ratio (HSR) as a measure, have demonstrated that DD-DWT outperforms conventional DWT in feature extraction and noise suppression. As a result, the proposed method is robust and effective in fault detection and diagnosis

A Componential Coding Neural Network based Signal Modelling for Condition Monitoring

Many condition monitoring (CM) techniques have been investigated for early fault detection and diagnosis in order to avoid unexpected breakdowns due to machinery failures. However, manual techniques require well-skilled labours which will increase the cost of the monitoring process and may not always be available at the site. One of the most promising approaches is to automate the monitoring process using artificial intelligence (AI) techniques. However, the majority of AI-based techniques have been developed in CM for the post-processing stage, whereas the critical tasks including feature extraction and selection are still manually processed. This study focuses on the extending AI techniques in all phases of CM process by using a Componential Coding Neural Network (CCNN) which has been found to have unique properties of being trained through unsupervised learning, capable of dealing with raw data sets, translation invariance and high computational efficiency. These advantages of CCNN make it particularly suitable for automated analysis of the vibration data arisen from typical machine components such as the rolling element bearings which exhibit periodic phenomena with high non-stationarity and strong noise contamination. The CCNN was evaluated using both simulated and experimental data collected from a healthy and two defective tapered roller bearings under different operating conditions. Both of the results showed the capability of CCNN in detecting the initial anomalies of roller element bearings