A Novel End-To-End Fault Diagnosis Approach for Rolling Bearings by Integrating Wavelet Packet Transform into Convolutional Neural Network Structures

A Novel Pipeline Corrosion Monitoring Method Based on Piezoelectric Active Sensing and CNN

In this study, a piezoelectric active sensing-based time reversal method was investigated for monitoring pipeline internal corrosion. An effective method that combines wavelet packet energy with a Convolutional Neural Network (CNN) was proposed to identify the internal corrosion status of pipelines. Two lead zirconate titanate (PZT) patches were pasted on the outer surface of the pipeline as actuators and sensors to generate and receive ultrasonic signals propagating through the inner wall of the pipeline. Then, the time reversal technique was employed to reverse the received response signal in the time domain, and then to retransmit it as an excitation signal to obtain the focused signal. Afterward, the wavelet packet transform was used to decompose the focused signal, and the wavelet packet energy (WPE) with large components was extracted as the input of the CNN model to rapidly identify the corrosion degree inside the pipeline. The corrosion experiments were conducted to verify the correctness of the proposed method. The occurrence and development of corrosion in pipelines were generated by electrochemical corrosion, and nine different depths of corrosion were imposed on the sample pipeline. The experimental results indicated that the classification accuracy exceeded 99.01%. Therefore, this method can quantitatively monitor the corrosion status of pipelines and can pinpoint the internal corrosion degree of pipelines promptly and accurately. The WPE-CNN model in combination with the proposed time reversal method has high application potential for monitoring pipeline internal corrosion.

Multiple Enhanced Sparse Representation via IACMDSR Model for Bearing Compound Fault Diagnosis

For the sake of addressing the issue of extracting multiple features embedded in a noise-heavy vibration signal for bearing compound fault diagnosis, a novel model based on improved adaptive chirp mode decomposition (IACMD) and sparse representation, namely IACMDSR, is developed in this paper. Firstly, the IACMD is employed to simultaneously separate the distinct fault types and extract multiple resonance frequencies induced by them. Next, an adaptive bilateral wavelet hyper-dictionary that digs deeper into the periodicity and waveform characteristics exhibited by the real fault impulse response is constructed to identify and reconstruct each type of fault-induced feature with the help of the orthogonal matching pursuit (OMP) algorithm. Finally, the fault characteristic frequency can be detected via an envelope demodulation analysis of the reconstructed signal. A simulation and two sets of experimental results confirm that the developed IACMDSR model is a powerful and versatile tool and consistently outperforms the leading MCKDSR and MCKDMWF models. Furthermore, the developed model has satisfactory capability in practical applications because the IACMD has no requirement for the input number of the signal components and the adaptive bilateral wavelet is powerfully matched to the real fault-induced impulse response.

A Bearing Fault Classification Framework Based on Image Encoding Techniques and a Convolutional Neural Network under Different Operating Conditions

Diagnostics of mechanical problems in manufacturing systems are essential to maintaining safety and minimizing expenditures. In this study, an intelligent fault classification model that combines a signal-to-image encoding technique and a convolution neural network (CNN) with the motor-current signal is proposed to classify bearing faults. In the beginning, we split the dataset into four parts, considering the operating conditions. Then, the original signal is segmented into multiple samples, and we apply the Gramian angular field (GAF) algorithm on each sample to generate two-dimensional (2-D) images, which also converts the time-series signals into polar coordinates. The image conversion technique eliminates the requirement of manual feature extraction and creates a distinct pattern for individual fault signatures. Finally, the resultant image dataset is used to design and train a 2-layer deep CNN model that can extract high-level features from multiple images to classify fault conditions. For all the experiments that were conducted on different operating conditions, the proposed method shows a high classification accuracy of more than 99% and proves that the GAF can efficiently preserve the fault characteristics from the current signal. Three built-in CNN structures were also applied to classify the images, but the simple structure of a 2-layer CNN proved to be sufficient in terms of classification results and computational time. Finally, we compare the experimental results from the proposed diagnostic framework with some state-of-the-art diagnostic techniques and previously published works to validate its superiority under inconsistent working conditions. The results verify that the proposed method based on motor-current signal analysis is a good approach for bearing fault classification in terms of classification accuracy and other evaluation parameters.

Bearing Fault Classification Using Ensemble Empirical Mode Decomposition and Convolutional Neural Network

Condition monitoring is used to track the unavoidable phases of rolling element bearings in an induction motor (IM) to ensure reliable operation in domestic and industrial machinery. The convolutional neural network (CNN) has been used as an effective tool to recognize and classify multiple rolling bearing faults in recent times. Due to the nonlinear and nonstationary nature of vibration signals, it is quite difficult to achieve high classification accuracy when directly using the original signal as the input of a convolution neural network. To evaluate the fault characteristics, ensemble empirical mode decomposition (EEMD) is implemented to decompose the signal into multiple intrinsic mode functions (IMFs) in this work. Then, based on the kurtosis value, insignificant IMFs are filtered out and the original signal is reconstructed with the rest of the IMFs so that the reconstructed signal contains the fault characteristics. After that, the 1-D reconstructed vibration signal is converted into a 2-D image using a continuous wavelet transform with information from the damage frequency band. This also transfers the signal into a time-frequency domain and reduces the nonstationary effects of the vibration signal. Finally, the generated images of various fault conditions, which possess a discriminative pattern relative to the types of faults, are used to train an appropriate CNN model. Additionally, with the reconstructed signal, two different methods are used to create an image to compare with our proposed image creation approach. The vibration signal is collected from a self-designed testbed containing multiple bearings of different fault conditions. Two other conventional CNN architectures are compared with our proposed model. Based on the results obtained, it can be concluded that the image generated with fault signatures not only accurately classifies multiple faults with CNN but can also be considered as a reliable and stable method for the diagnosis of fault bearings.

An Improved Variational Mode Decomposition and Its Application on Fault Feature Extraction of Rolling Element Bearing

The fault diagnosis of rolling element bearing is of great significance to avoid serious accidents and huge economic losses. However, the characteristics of the nonlinear, non-stationary vibration signals make the fault feature extraction of signal become a challenging work. This paper proposes an improved variational mode decomposition (IVMD) algorithm for the fault feature extraction of rolling bearing, which has the advantages of extracting the optimal fault feature from the decomposed mode and overcoming the noise interference. The Shuffled Frog Leap Algorithm (SFLA) is employed in the optimal adaptive selection of mode number K and bandwidth control parameter α. A multi-objective evaluation function, which is based on the envelope entropy, kurtosis and correlation coefficients, is constructed to select the optimal mode component. The efficiency coefficient method (ECM) is utilized to transform the multi-objective optimization problem into a single-objective optimization problem. The envelope spectrum technique is used to analyze the signals reconstructed by the optimal mode components. The proposed IVMD method is evaluated by simulation and practical bearing vibration signals under different conditions. The results show that the proposed method can improve the decomposition accuracy of the signal and the adaptability of the influence parameters and realize the effective extraction of the bearing vibration signal.

Fault Detection and Identification Method for Quadcopter Based on Airframe Vibration Signals

Quadcopters are widely used in a variety of military and civilian mission scenarios. Real-time online detection of the abnormal state of the quadcopter is vital to the safety of aircraft. Existing data-driven fault detection methods generally usually require numerous sensors to collect data. However, quadcopter airframe space is limited. A large number of sensors cannot be loaded, meaning that it is difficult to use additional sensors to capture fault signals for quadcopters. In this paper, without additional sensors, a Fault Detection and Identification (FDI) method for quadcopter blades based on airframe vibration signals is proposed using the airborne acceleration sensor. This method integrates multi-axis data information and effectively detects and identifies quadcopter blade faults through Long and Short-Term Memory (LSTM) network models. Through flight experiments, the quadcopter triaxial accelerometer data are collected for airframe vibration signals at first. Then, the wavelet packet decomposition method is employed to extract data features, and the standard deviations of the wavelet packet coefficients are employed to form the feature vector. Finally, the LSTM-based FDI model is constructed for quadcopter blade FDI. The results show that the method can effectively detect and identify quadcopter blade faults with a better FDI performance and a higher model accuracy compared with the Back Propagation (BP) neural network-based FDI model.

Intelligent Diagnosis towards Hydraulic Axial Piston Pump Using a Novel Integrated CNN Model

As a critical part of a hydraulic transmission system, a hydraulic axial piston pump plays an indispensable role in many significant industrial fields. Owing to the practical undesirable working environment and hidden faults, it is challenging to precisely and effectively detect and diagnose the varying fault in the engineering. Deep learning-based technology presents special strengths in processing mechanical big data. It can simultaneously complete the feature extraction and classification, and achieve the automatic information learning. The popular convolutional neural network (CNN) is exploited for its potent ability of image processing. In this paper, a novel combined intelligent method is developed for fault diagnosis towards a hydraulic axial piston pump. First, the conversion of signals to images is conducted via continuous wavelet transform; the effective feature is preliminarily extracted from the transformed time-frequency images. Second, a novel deep CNN model is constructed to achieve the fault classification. To disclose the potential learning in the disparate layers of the CNN model, the visualization of reduced features is performed by employing t-distributed stochastic neighbor embedding. The effectiveness and stability of the proposed model are validated through the experiments. With the proposed method, different fault types can be precisely identified and high classification accuracy is achieved in a hydraulic axial piston pump.

An Integrated Deep Learning Method towards Fault Diagnosis of Hydraulic Axial Piston Pump

A hydraulic axial piston pump is the essential component of a hydraulic transmission system and plays a key role in modern industry. Considering varying working conditions and the implicity of frequent faults, it is difficult to accurately monitor the machinery faults in the actual operating process by using current fault diagnosis methods. Hence, it is urgent and significant to investigate effective and precise fault diagnosis approaches for pumps. Owing to the advantages of intelligent fault diagnosis methods in big data processing, methods based on deep learning have accomplished admirable performance for fault diagnosis of rotating machinery. The prevailing convolutional neural network (CNN) displays desirable automatic learning ability. Therefore, an integrated intelligent fault diagnosis method is proposed based on CNN and continuous wavelet transform (CWT), combining the feature extraction and classification. Firstly, CWT is used to convert the raw vibration signals into time-frequency representations and achieve the extraction of image features. Secondly, a new framework of deep CNN is established via designing the convolutional layers and sub-sampling layers. The learning process and results are visualized by t-distributed stochastic neighbor embedding (t-SNE). The results of the experiment present a higher classification accuracy compared with other models. It is demonstrated that the proposed approach is effective and stable for fault diagnosis of a hydraulic axial piston pump.

Fault Diagnosis of Rolling Bearings Based on a Residual Dilated Pyramid Network and Full Convolutional Denoising Autoencoder

Intelligent fault diagnosis algorithm for rolling bearings has received increasing attention. However, in actual industrial environments, most rolling bearings work under severe working conditions of variable speed and strong noise, which makes the performance of many intelligent fault diagnosis methods deteriorate sharply. In this regard, this paper proposes a new intelligent diagnosis algorithm for rolling bearing faults based on a residual dilated pyramid network and full convolutional denoising autoencoder (RDPN-FCDAE). First, a continuous wavelet transform (CWT) is used to convert original vibration signals into time-frequency images. Secondly, a deep two-stage RDPN-FCDAE model is constructed, which is divided into three parts: encoding network, decoding network and classification network. In order to obtain efficient expression of data denoising feature of encoding network, time-frequency images are first input into the encoding-decoding network for unsupervised pre-training. Then pre-trained coding network and classification network are combined into residual dilated pyramid full convolutional network (RDPFCN) for parameter fine-tuning and testing. The proposed method is applied to bearing vibration datasets of test rig with different speeds and noise modes. Compared with representative machine learning and deep learning method, the results show that the algorithm proposed is superior to other methods in diagnostic accuracy, noise robustness and feature segmentation ability.