Vibration Analysis for Fault Detection of Wind Turbine Drivetrains-A Comprehensive Investigation

Fusion of Audio and Vibration Signals for Bearing Fault Diagnosis Based on a Quadratic Convolution Neural Network

In this paper, a quadratic convolution neural network (QCNN) using both audio and vibration signals is utilized for bearing fault diagnosis. Specifically, to make use of multi-modal information for bearing fault diagnosis, the audio and vibration signals are first fused together using a 1 × 1 convolution. Then, a quadratic convolution neural network is applied for the fusion feature extraction. Finally, a decision module is designed for fault classification. The proposed method utilizes the complementary information of audio and vibration signals, and is insensitive to noise. The experimental results show that the accuracy of the proposed method can achieve high accuracies for both single and multiple bearing fault diagnosis in the noisy situations. Moreover, the combination of two-modal data helps improve the performance under all conditions.

Analysis of Vibration Signals Based on Machine Learning for Crack Detection in a Low-Power Wind Turbine

Currently, renewable energies, including wind energy, have been experiencing significant growth. Wind energy is transformed into electric energy through the use of wind turbines (WTs), which are located outdoors, making them susceptible to harsh weather conditions. These conditions can cause different types of damage to WTs, degrading their lifetime and efficiency, and, consequently, raising their operating costs. Therefore, condition monitoring and the detection of early damages are crucial. One of the failures that can occur in WTs is the occurrence of cracks in their blades. These cracks can lead to the further deterioration of the blade if they are not detected in time, resulting in increased repair costs. To effectively schedule maintenance, it is necessary not only to detect the presence of a crack, but also to assess its level of severity. This work studies the vibration signals caused by cracks in a WT blade, for which four conditions (healthy, light, intermediate, and severe cracks) are analyzed under three wind velocities. In general, as the proposed method is based on machine learning, the vibration signal analysis consists of three stages. Firstly, for feature extraction, statistical and harmonic indices are obtained; then, the one-way analysis of variance (ANOVA) is used for the feature selection stage; and, finally, the k-nearest neighbors algorithm is used for automatic classification. Neural networks, decision trees, and support vector machines are also used for comparison purposes. Promising results are obtained with an accuracy higher than 99.5%.

Framework for Bidirectional Knowledge-Based Maintenance of Wind Turbines

Artificial intelligence (AI) techniques, such as machine learning (ML), are being developed and applied for the monitoring, tracking, and fault diagnosis of wind turbines. Current prediction systems are largely limited by their inherent disadvantages for wind turbines. For example, frequency or vibration analysis simulations at a part scale require a great deal of computational power and take considerable time, an aspect that can be essential and expensive in the case of a breakdown, especially if it is offshore. An integrated digital framework for wind turbine maintenance is proposed in this study. With this framework, predictions can be made both forward and backward, breaking down barriers between process variables and key attributes. Prediction accuracy in both directions is enhanced by process knowledge. An analysis of the complicated relationships between process parameters and process attributes is demonstrated in a case study based on a wind turbine prototype. Due to the harsh environments in which wind turbines operate, the proposed method should be very useful for supervising and diagnosing faults.

Compound Fault Diagnosis of a Wind Turbine Gearbox Based on MOMEDA and Parallel Parameter Optimized Resonant Sparse Decomposition

Wind turbines usually operate in harsh environments. The gearbox, the key component of the transmission chain in wind turbines, can easily be affected by multiple factors during the operation process and develop compound faults. Different types of faults can occur, coupled with each other and staggered interference. Thus, a challenge is to extract the fault characteristics from the composite fault signal to improve the reliability and the accuracy of compound fault diagnosis. To address the above problems, we propose a compound fault diagnosis method for wind turbine gearboxes based on multipoint optimal minimum entropy deconvolution adjusted (MOMEDA) and parallel parameter optimized resonant sparse decomposition (RSSD). Firstly, the MOMEDA is applied to the preprocess, setting the deconvolution period with different fault frequency types to eliminate the interference of the transmission path and environmental noise, while decoupling and separating the different types of single faults. Then, the RSSD method with parallel parameter optimization is applied for decomposing the preprocessed signal to obtain the low resonance components, further suppressing the interference components and enhancing the periodic fault characteristics. Finally, envelope demodulation of the enhanced signal is applied to extract the fault features and identify the different fault types. The effectiveness of the proposed method was verified using the actual data from the wind turbine gearbox. In addition, a comparison with some existing methods demonstrates the superiority of this method for decoupling composite fault characteristics.

A Probabilistic Bayesian Parallel Deep Learning Framework for Wind Turbine Bearing Fault Diagnosis

The technology of fault diagnosis helps improve the reliability of wind turbines. Difficulties in feature extraction and low confidence in diagnostic results are widespread in the process of deep learning-based fault diagnosis of wind turbine bearings. Therefore, a probabilistic Bayesian parallel deep learning (BayesianPDL) framework is proposed and then achieves fault classification. A parallel deep learning (PDL) framework is proposed to solve the problem of difficult feature extraction of bearing faults. Next, the weights and biases in the PDL framework are converted from deterministic values to probability distributions. In this way, an uncertainty-aware method is explored to achieve reliable machine fault diagnosis. Taking the fault signal of the gearbox output shaft bearing of a wind turbine generator in a wind farm as an example, the diagnostic accuracy of the proposed method can reach 99.14%, and the confidence in diagnostic results is higher than other comparison methods. Experimental results show that the BayesianPDL framework has unique advantages in the fault diagnosis of wind turbine bearings.

Fault Detection for Wind Turbine Blade Bolts Based on GSG Combined with CS-LightGBM

Aiming at the problem of class imbalance in the wind turbine blade bolts operation-monitoring dataset, a fault detection method for wind turbine blade bolts based on Gaussian Mixture Model-Synthetic Minority Oversampling Technique-Gaussian Mixture Model (GSG) combined with Cost-Sensitive LightGBM (CS-LightGBM) was proposed. Since it is difficult to obtain the fault samples of blade bolts, the GSG oversampling method was constructed to increase the fault samples in the blade bolt dataset. The method obtains the optimal number of clusters through the BIC criterion, and uses the GMM based on the optimal number of clusters to optimally cluster the fault samples in the blade bolt dataset. According to the density distribution of fault samples in inter-clusters, we synthesized new fault samples using SMOTE in an intra-cluster. This retains the distribution characteristics of the original fault class samples. Then, we used the GMM with the same initial cluster center to cluster the fault class samples that were added to new samples, and removed the synthetic fault class samples that were not clustered into the corresponding clusters. Finally, the synthetic data training set was used to train the CS-LightGBM fault detection model. Additionally, the hyperparameters of CS-LightGBM were optimized by the Bayesian optimization algorithm to obtain the optimal CS-LightGBM fault detection model. The experimental results show that compared with six models including SMOTE-LightGBM, CS-LightGBM, K-means-SMOTE-LightGBM, etc., the proposed fault detection model is superior to the other comparison methods in the false alarm rate, missing alarm rate and F1-score index. The method can well realize the fault detection of large wind turbine blade bolts.

A Hybrid Finite Element Method–Analytical Model for Classifying the Effects of Cracks on Gear Train Systems Using Artificial Neural Networks

Rotating machinery is fundamental in industry, gearboxes especially. However, failures may occur in their transmission components due to regular usage over long periods of time, even when operations are not intense. To avoid such failures, Structural Health Monitoring (SHM) techniques for damage prediction and in-advance detection can be applied. In this regard, correlations between measured signal variations and damage can be inspected using Artificial Intelligence (AI), which demands large numbers of data for training. Since obtaining signal samples of damaged components experimentally is currently unviable for complex systems due to destructive test costs, model-based numerical approaches are to be explored to solve this problem. To address this issue, this work applied an innovative hybrid Finite Element Method (FEM)–analytical approach, reducing computational effort and increasing performance with respect to traditional FEM. With this methodology, a system can be simulated with accuracy and without geometrical simplifications for healthy and damaged cases. Indeed, considering different positions and dimensions of damages (e.g., cracks) on the tooth roots of gears can offer new ways of damage investigation. As a reference to validate healthy systems and damage cases in terms of eigenfrequencies, a back-to-back test rig was used. Numerical simulations were performed for different cases, resulting in vibrational spectra for systems with no damage, with damage, and with damage of different intensities. The vibration spectra were used as data to train an Artificial Neural Network (ANN) to predict the machine state by Condition Monitoring (CM) and Fault Diagnosis (FD). For predicting the health and the intensity of damage to a system, classification and multi-class classification methods were implemented, respectively. Both sets of classification results presented good prediction agreement.

A Model-Agnostic Meta-Baseline Method for Few-Shot Fault Diagnosis of Wind Turbines

The technology of fault diagnosis is helpful to improve the reliability of wind turbines, and further reduce the operation and maintenance cost at wind farms. However, in reality, wind turbines are not allowed to operate with faults, so few fault samples could be obtained. With a small amount of training data, traditional fault diagnosis models that need huge samples under a deep learning framework are difficult to maintain with high accuracy and effectiveness. Few-shot learning can effectively solve the problem of overfitting caused by fewer fault samples in model training. In view of model-agnostic meta-learning (MAML), this paper proposes a model for few-shot fault diagnosis of the wind turbines drivetrain, which is named model-agnostic meta-baseline (MAMB). The training data is input to the base classification model for pre-training, then, some data is randomly selected from the training set to form multiple meta-learning tasks that are utilized to train the MAML to finally fine-tune the later layers of the model at a smaller learning rate. The proposed model was analyzed by the small samples of the bearing data from Case Western Reserve University (CWRU) data, the generator bearings, and gearboxes vibration data in wind turbines under randomly changing operating conditions. The results verified that the proposed method was superior in one-shot, five-shot, and ten-shot tasks of wind turbines.

Optical Accelerometers for Detecting Low-Frequency Micro-Vibrations

Optical accelerometers are high-precision inertial sensors that use optical measurement technology to achieve high-precision and electromagnetic interference-resistant acceleration measurements. With the intensive research and development of optical accelerometers in recent years, their applications in inertial navigation, structural health monitoring, precision vibration isolation systems, wind turbine fault monitoring, earthquake monitoring, and other low-frequency vibration detection have flourished. Optical accelerometers have various schemes; however, their characteristics vary considerably due to different optical modulation schemes. This study aims to address the lack of systematic evaluation of currently available low-frequency optical accelerometers. Optical accelerometers can be classified into four categories in accordance with their optical modulation schemes: optical path-, optical intensity-, optical phase-, and optical wave-length-modulated accelerometers. The typical performance, advantages and disadvantages, and possible application scenarios of various optical accelerometers are summarized. This study also presents the current status and trends of low-frequency optical accelerometers in consideration of the growing demand for high-precision, low-frequency acceleration measurements.

Digital Twins for Wind Energy Conversion Systems: A Literature Review of Potential Modelling Techniques Focused on Model Fidelity and Computational Load

The Industry 4.0 concept of a Digital Twin will bring many advantages for wind energy conversion systems, e.g., in condition monitoring, predictive maintenance and the optimisation of control or design parameters. A virtual replica is at the heart of a digital twin. To construct a virtual replica, appropriate modelling techniques must be selected for the turbine components. These models must be chosen with the intended use case of the digital twin in mind, finding a proper balance between the model fidelity and computational load. This review article presents an overview of the recent literature on modelling techniques for turbine aerodynamics, structure and drivetrain mechanics, the permanent magnet synchronous generator, the power electronic converter and the pitch and yaw systems. For each component, a balanced overview is given of models with varying model fidelity and computational load, ranging from simplified lumped parameter models to advanced numerical Finite Element Method (FEM)-based models. The results of the literature review are presented graphically to aid the reader in the model selection process. Based on this review, a high-level structure of a digital twin is proposed together with a virtual replica with a minimum computational load. The concept of a multi-level hierarchical virtual replica is presented.

Fault Diagnosis of a Wind Turbine Gearbox Based on Improved Variational Mode Algorithm and Information Entropy

The working environment of wind turbine gearboxes is complex, complicating the effective monitoring of their running state. In this paper, a new gearbox fault diagnosis method based on improved variational mode decomposition (IVMD), combined with time-shift multi-scale sample entropy (TSMSE) and a sparrow search algorithm-based support vector machine (SSA-SVM), is proposed. Firstly, a novel algorithm, IVMD, is presented for solving the problem where VMD parameters (K and α) need to be selected in advance, which mainly contains two steps: the maximum kurtosis index is employed to preliminarily determine a series of local optimal decomposition parameters (K and α), then from the local parameters, the global optimum parameters are selected based on the minimum energy loss coefficient (ELC). After decomposition by IVMD, the raw signal is divided into K intrinsic mode functions (IMFs), the optimal IMF(s) with abundant fault information is (are) chosen based on the minimum envelopment entropy criterion. Secondly, the time-shift technique is introduced to information entropy, the time-shift multi-scale sample entropy algorithm is applied for the analysis of the complexity of the chosen optimal IMF and extract fault feature vectors. Finally, the sparrow search algorithm, which takes the classification error rate of SVM as the fitness function, is used to adaptively optimize the SVM parameters. Next, the extracted TSMSEs are input into the SSA-SVM model as the feature vector to identify the gear signal types under different conditions. The simulation and experimental results confirm that the proposed method is feasible and superior in gearbox fault diagnosis when compared with other methods.