Unsupervised Feature-Construction-Based Motor Fault Diagnosis.

Any bearing faults are a leading cause of motor damage and bring economic losses. Fast and accurate identification of bearing faults is valuable for preventing damaging the whole equipment and continuously running industrial processes without interruption. Vibration signals from a running motor can be utilized to diagnose a bearing health condition. This study proposes a detection method for bearing faults based on two types of neural networks from motor vibration data. The proposed method uses an autoencoder neural network for constructing a new motor vibration feature and a feed-forward neural network for the final detection. The constructed signal feature enhances the prediction performance by focusing more on a fault type that is difficult to detect. We conducted experiments on the CWRU bearing datasets. The experimental study shows that the proposed method improves the performance of the feed-forward neural network and outperforms the other machine learning algorithms.

Risk-Based Fault Detection Using Bayesian Networks Based on Failure Mode and Effect Analysis.

In this article, the authors focus on the introduction of a hybrid method for risk-based fault detection (FD) using dynamic principal component analysis (DPCA) and failure method and effect analysis (FMEA) based Bayesian networks (BNs). The FD problem has garnered great interest in industrial application, yet methods for integrating process risk into the detection procedure are still scarce. It is, however, critical to assess the risk each possible process fault holds to differentiate between non-safety-critical and safety-critical abnormalities and thus minimize alarm rates. The proposed method utilizes a BN established through FMEA analysis of the supervised process and the results of dynamical principal component analysis to estimate a modified risk priority number (RPN) of different process states. The RPN is used parallel to the FD procedure, incorporating the results of both to differentiate between process abnormalities and highlight critical issues. The method is showcased using an industrial benchmark problem as well as the model of a reactor utilized in the emerging liquid organic hydrogen carrier (LOHC) technology.

Performance Assessment of Pneumatic-Driven Automatic Valves to Improve Pipeline Fault Detection Procedure by Fast Transient Tests.

The use of fast transients for fault detection in long transmission networks makes the generation of controlled transients crucial. In order to maximise the information that can be extracted from the measured pressure time history (pressure signal), the transients must meet certain requirements. In particular, the manoeuvre that generates the transient must be fast and repeatable, and must produce a pressure wave that is as sharp as possible, without spurious pressure oscillations. This implies the use of small-diameter valves and often pneumatically operated automatic valves. In the present work, experimental transient tests are carried out at the Water Engineering Laboratory (WEL) of the University of Perugia using a butterfly valve and a ball pneumatic-driven valve to generate pressure waves in a pressurised copper pipe. A camera is used to monitor the valve displacement, while the pressure is measured by a pressure transducer close to the downstream end of the pipe where the pneumatic valve is installed. The experimental data are analysed to characterise the valve performance and to compare the two geometries in terms of valve closing dynamics, the sharpness of the generated pressure wave and the stability of the pressure time history. The present work demonstrates how the proposed approach can be very effective in easily characterising the transient dynamics.

Resilient Event-Based Fuzzy Fault Detection for DC Microgrids in Finite-Frequency Domain against DoS Attacks.

This paper addresses the problem of fault detection in DC microgrids in the presence of denial-of-service (DoS) attacks. To deal with the nonlinear term in DC microgrids, a Takagi-Sugeno (T-S) model is employed. In contrast to the conventional approach of utilizing current sampling data in the traditional event-triggered mechanism (ETM), a novel integrated ETM employs historical information from measured data. This innovative strategy mitigates the generation of additional triggering packets resulting from random perturbations, thus reducing redundant transmission data. Under the assumption of faults occurring within a finite-frequency domain, a resilient event-based H-/H∞ fault detection filter (FDF) is designed to withstand DoS attacks. The exponential stability conditions are derived in the form of linear matrix inequalities to ensure the performance of fault detected systems. Finally, the simulation results are presented, demonstrating that the designed FDF effectively detects finite-frequency faults in time even under DoS attacks. Furthermore, the FDF exhibits superior fault detection sensitivity compared to the conventional H∞ method, thus confirming the efficacy of the proposed approach. Additionally, it is observed that a trade-off exists between fault detection performance and the data releasing rate (DRR).

Industrial Fault Detection Employing Meta Ensemble Model Based on Contact Sensor Ultrasonic Signal.

Ultrasonic diagnostics is the earliest way to predict industrial faults. Usually, a contact microphone is employed for detection, but the recording will be contaminated with noise. In this paper, a dataset that contains 10 main faults of pipelines and motors is analyzed from which 30 different features in the time and frequency domains are extracted. Afterward, for dimensionality reduction, principal component analysis (PCA), linear discriminant analysis (LDA), and t-distributed stochastic neighbor embedding (t-SNE) are performed. In the subsequent phase, recursive feature elimination (RFE) is employed as a strategic method to analyze and select the most relevant features for the classifiers. Next, predictive models consisting of k-Nearest Neighbor (KNN), Logistic Regression (LR), Decision Tree (DT), Gaussian Naive Bayes (GNB), and Support Vector Machine (SVM) are employed. Then, in order to solve the classification problem, a stacking classifier based on a meta-classifier which combines multiple classification models is introduced. Furthermore, the k-fold cross-validation technique is employed to assess the effectiveness of the model in handling new data for the evaluation of experimental results in ultrasonic fault detection. With the proposed method, the accuracy is around 5% higher over five cross folds with the least amount of variation. The timing evaluation of the meta model on the 64 MHz Cortex M4 microcontroller unit (MCU) revealed an execution time of 11 ms, indicating it could be a promising solution for real-time monitoring.

Research on Fault Detection by Flow Sequence for Industrial Internet of Things in Sewage Treatment Plant Case.

Classifying the flow subsequences of sensor networks is an effective way for fault detection in the Industrial Internet of Things (IIoT). Traditional fault detection algorithms identify exceptions by a single abnormal dataset and do not pay attention to the factors such as electromagnetic interference, network delay, sensor sample delay, and so on. This paper focuses on fault detection by continuous abnormal points. We proposed a fault detection algorithm within the module of sequence state generated by unsupervised learning (SSGBUL) and the module of integrated encoding sequence classification (IESC). Firstly, we built a network module based on unsupervised learning to encode the flow sequence of the different network cards in the IIoT gateway, and then combined the multiple code sequences into one integrated sequence. Next, we classified the integrated sequence by comparing the integrated sequence with the encoding fault type. The results obtained from the three IIoT datasets of a sewage treatment plant show that the accuracy of the SSGBUL-IESC algorithm exceeds 90% with subsequence length 10, which is significantly higher than the accuracies of the dynamic time warping (DTW) algorithm and the time series forest (TSF) algorithm. The proposed algorithm reaches the classification requirements for fault detection for the IIoT.

Lightweight Transmission Line Fault Detection Method Based on Leaner YOLOv7-Tiny.

Aiming to address the issues of parameter complexity and high computational load in existing fault detection algorithms for transmission lines, which hinder their deployment on devices like drones, this study proposes a novel lightweight model called Leaner YOLOv7-Tiny. The primary goal is to swiftly and accurately detect typical faults in transmission lines from aerial images. This algorithm inherits the ELAN structure from YOLOv7-Tiny network and replaces its backbone with depthwise separable convolutions to reduce model parameters. By integrating the SP attention mechanism, it fuses multi-scale information, capturing features across various scales to enhance small target recognition. Finally, an improved FCIoU Loss function is introduced to balance the contribution of high-quality and low-quality samples to the loss function, expediting model convergence and boosting detection accuracy. Experimental results demonstrate a 20% reduction in model size compared to the original YOLOv7-Tiny algorithm. Detection accuracy for small targets surpasses that of current mainstream lightweight object detection algorithms. This approach holds practical significance for transmission line fault detection.

Smart Sensor-Based Monitoring Technology for Machinery Fault Detection.

Rotary machines commonly use rolling element bearings to support rotation of the shafts. Most machine performance imperfections are related to bearing defects. Thus, reliable bearing condition monitoring systems are critically needed in industries to provide early warning of bearing fault so as to prevent machine performance degradation and reduce maintenance costs. The objective of this paper is to develop a smart monitoring system for real-time bearing fault detection and diagnostics. Firstly, a smart sensor-based data acquisition (DAQ) system is developed for wireless vibration signal collection. Secondly, a modified variational mode decomposition (MVMD) technique is proposed for nonstationary signal analysis and bearing fault detection. The proposed MVMD technique has several processing steps: (1) the signal is decomposed into a series of intrinsic mode functions (IMFs); (2) a correlation kurtosis method is suggested to choose the most representative IMFs and construct the analytical signal; (3) envelope spectrum analysis is performed to identify the representative features and to predict bearing fault. The effectiveness of the developed smart sensor DAQ system and the proposed MVMD technique is examined by systematic experimental tests.

Recent Advances in Intelligent Algorithms for Fault Detection and Diagnosis.

Fault-finding diagnostics is a model-driven approach that identifies a system's malfunctioning portion. It uses residual generators to identify faults, and various methods like isolation techniques and structural analysis are used. However, diagnostic equipment doesn't measure the remaining signal-to-noise ratio. Residual selection identifies fault-detecting generators. Fault detective diagnostic (FDD) approaches have been investigated and implemented for various industrial processes. However, industrial operations make it difficult to implement FDD techniques. To bridge the gap between theoretical methodologies and implementations, hybrid approaches and intelligent procedures are needed. Future research should focus on improving fault prognosis, allowing for accurate prediction of process failures and avoiding safety hazards. Real-time and comprehensive FDD strategies should be implemented in the age of big data.

An Improved Method for Detecting Crane Wheel-Rail Faults Based on YOLOv8 and the Swin Transformer.

In the realm of special equipment, significant advancements have been achieved in fault detection. Nonetheless, faults originating in the equipment manifest with diverse morphological characteristics and varying scales. Certain faults necessitate the extrapolation from global information owing to their occurrence in localized areas. Simultaneously, the intricacies of the inspection area's background easily interfere with the intelligent detection processes. Hence, a refined YOLOv8 algorithm leveraging the Swin Transformer is proposed, tailored for detecting faults in special equipment. The Swin Transformer serves as the foundational network of the YOLOv8 framework, amplifying its capability to concentrate on comprehensive features during the feature extraction, crucial for fault analysis. A multi-head self-attention mechanism regulated by a sliding window is utilized to expand the observation window's scope. Moreover, an asymptotic feature pyramid network is introduced to augment spatial feature extraction for smaller targets. Within this network architecture, adjacent low-level features are merged, while high-level features are gradually integrated into the fusion process. This prevents loss or degradation of feature information during transmission and interaction, enabling accurate localization of smaller targets. Drawing from wheel-rail faults of lifting equipment as an illustration, the proposed method is employed to diagnose an expanded fault dataset generated through transfer learning. Experimental findings substantiate that the proposed method in adeptly addressing numerous challenges encountered in the intelligent fault detection of special equipment. Moreover, it outperforms mainstream target detection models, achieving real-time detection capabilities.

Particle-Filter-Based Fault Diagnosis for the Startup Process of an Open-Cycle Liquid-Propellant Rocket Engine.

This study introduces a fault diagnosis algorithm based on particle filtering for open-cycle liquid-propellant rocket engines (LPREs). The algorithm serves as a model-based method for the startup process, accounting for more than 30% of engine failures. Similar to the previous fault detection and diagnosis (FDD) algorithm for the startup process, the algorithm in this study is composed of a nonlinear filter to generate residuals, a residual analysis, and a multiple-model (MM) approach to detect and diagnose faults from the residuals. In contrast to the previous study, this study makes use of the modified cumulative sum (CUSUM) algorithm, widely used in change-detection monitoring, and a particle filter (PF), which is theoretically the most accurate nonlinear filter. The algorithm is confirmed numerically using the CUSUM and MM methods. Subsequently, the FDD algorithm is compared with an algorithm from a previous study using a Monte Carlo simulation. Through a comparative analysis of algorithmic performance, this study demonstrates that the current PF-based FDD algorithm outperforms the algorithm based on other nonlinear filters.

Helical Gearbox Defect Detection with Machine Learning Using Regular Mesh Components and Sidebands.

The current paper presents helical gearbox defect detection models built from raw vibration signals measured using a triaxial accelerometer. Gear faults, such as localized pitting, localized wear on helical pinion tooth flanks, and low lubricant level, are under observation for three rotating velocities of the actuator and three load levels at the speed reducer output. The emphasis is on the strong connection between the gear faults and the fundamental meshing frequency GMF, its harmonics, and the sidebands found in the vibration spectrum as an effect of the amplitude modulation (AM) and phase modulation (PM). Several sets of features representing powers on selected frequency bands or/and associated peak amplitudes from the vibration spectrum, and also, for comparison, time-domain and frequency-domain statistical feature sets, are proposed as predictors in the defect detection task. The best performing detection model, with a testing accuracy of 99.73%, is based on SVM (Support Vector Machine) with a cubic kernel, and the features used are the band powers associated with six GMF harmonics and two sideband pairs for all three accelerometer axes, regardless of the rotation velocities and the load levels.

Unsupervised Transfer Learning Method via Cycle-Flow Adversarial Networks for Transient Fault Detection under Various Operation Conditions.

The efficient fault detection (FD) of traction control systems (TCSs) is crucial for ensuring the safe operation of high-speed trains. Transient faults (TFs) can arise due to prolonged operation and harsh environmental conditions, often being masked by background noise, particularly during dynamic operating conditions. Moreover, acquiring a sufficient number of samples across the entire scenario presents a challenging task, resulting in imbalanced data for FD. To address these limitations, an unsupervised transfer learning (TL) method via federated Cycle-Flow adversarial networks (CFANs) is proposed to effectively detect TFs under various operating conditions. Firstly, a CFAN is specifically designed for extracting latent features and reconstructing data in the source domain. Subsequently, a transfer learning framework employing federated CFANs collectively adjusts the modified knowledge resulting from domain alterations. Finally, the designed federated CFANs execute transient FD by constructing residuals in the target domain. The efficacy of the proposed methodology is demonstrated through comparative experiments.

Cyber-Physical Distributed Intelligent Motor Fault Detection.

This research paper explores the realm of fault detection in distributed motors through the vision of the Internet of electrical drives. This paper aims at employing artificial neural networks supported by the data collected by the Internet of distributed devices. Cross-verification of results offers reliable diagnosis of industrial motor faults. The proposed methodology involves the development of a cyber-physical system architecture and mathematical modeling framework for efficient fault detection. The mathematical model is designed to capture the intricate relationships within the cyber-physical system, incorporating the dynamic interactions between distributed motors and their edge controllers. Fast Fourier transform is employed for signal processing, enabling the extraction of meaningful frequency features that serve as indicators of potential faults. The artificial neural network based fault detection system is integrated with the solution, utilizing its ability to learn complex patterns and adapt to varying motor conditions. The effectiveness of the proposed framework and model is demonstrated through experimental results. The experimental setup involves diverse fault scenarios, and the system's performance is evaluated in terms of accuracy, sensitivity, and false positive rates.

An Optimal Spatio-Temporal Hybrid Model Based on Wavelet Transform for Early Fault Detection.

An optimal spatio-temporal hybrid model (STHM) based on wavelet transform (WT) is proposed to improve the sensitivity and accuracy of detecting slowly evolving faults that occur in the early stage and easily submerge with noise in complex industrial production systems. Specifically, a WT is performed to denoise the original data, thus reducing the influence of background noise. Then, a principal component analysis (PCA) and the sliding window algorithm are used to acquire the nearest neighbors in both spatial and time dimensions. Subsequently, the cumulative sum (CUSUM) and the mahalanobis distance (MD) are used to reconstruct the hybrid statistic with spatial and temporal sequences. It helps to enhance the correlation between high-frequency temporal dynamics and space and improves fault detection precision. Moreover, the kernel density estimation (KDE) method is used to estimate the upper threshold of the hybrid statistic so as to optimize the fault detection process. Finally, simulations are conducted by applying the WT-based optimal STHM in the early fault detection of the Tennessee Eastman (TE) process, with the aim of proving that the fault detection method proposed has a high fault detection rate (FDR) and a low false alarm rate (FAR), and it can improve both production safety and product quality.

Entropy-Based Methods for Motor Fault Detection: A Review.

In the signal analysis context, the entropy concept can characterize signal properties for detecting anomalies or non-representative behaviors in fiscal systems. In motor fault detection theory, entropy can measure disorder or uncertainty, aiding in detecting and classifying faults or abnormal operation conditions. This is especially relevant in industrial processes, where early motor fault detection can prevent progressive damage, operational interruptions, or potentially dangerous situations. The study of motor fault detection based on entropy theory holds significant academic relevance too, effectively bridging theoretical frameworks with industrial exigencies. As industrial sectors progress, applying entropy-based methodologies becomes indispensable for ensuring machinery integrity based on control and monitoring systems. This academic endeavor enhances the understanding of signal processing methodologies and accelerates progress in artificial intelligence and other modern knowledge areas. A wide variety of entropy-based methods have been employed for motor fault detection. This process involves assessing the complexity of measured signals from electrical motors, such as vibrations or stator currents, to form feature vectors. These vectors are then fed into artificial-intelligence-based classifiers to distinguish between healthy and faulty motor signals. This paper discusses some recent references to entropy methods and a summary of the most relevant results reported for fault detection over the last 10 years.

A Novel Fault Diagnosis Method of High-Speed Train Based on Few-Shot Learning.

Ensuring the safe and stable operation of high-speed trains necessitates real-time monitoring and diagnostics of their suspension systems. While machine learning technology is widely employed for industrial equipment fault diagnosis, its effective application relies on the availability of a large dataset with annotated fault data for model training. However, in practice, the availability of informational data samples is often insufficient, with most of them being unlabeled. The challenge arises when traditional machine learning methods encounter a scarcity of training data, leading to overfitting due to limited information. To address this issue, this paper proposes a novel few-shot learning method for high-speed train fault diagnosis, incorporating sensor-perturbation injection and meta-confidence learning to improve detection accuracy. Experimental results demonstrate the superior performance of the proposed method, which introduces perturbations, compared to existing methods. The impact of perturbation effects and class numbers on fault detection is analyzed, confirming the effectiveness of our learning strategy.

Differential Entropy-Based Fault-Detection Mechanism for Power-Constrained Networked Control Systems.

In this work, we consider the design of power-constrained networked control systems (NCSs) and a differential entropy-based fault-detection mechanism. For the NCS design of the control loop, we consider faults in the plant gain and unstable plant pole locations, either due to natural causes or malicious intent. Since the power-constrained approach utilized in the NCS design is a stationary approach, we then discuss the finite-time approximation of the power constraints for the relevant control loop signals. The network under study is formed by two additive white Gaussian noise (AWGN) channels located on the direct and feedback paths of the closed control loop. The finite-time approximation of the controller output signal allows us to estimate its differential entropy, which is used in our proposed fault-detection mechanism. After fault detection, we propose a fault-identification mechanism that is capable of correctly discriminating faults. Finally, we discuss the extension of the contributions developed here to future research directions, such as fault recovery and control resilience.

RAIM and Failure Mode Slope: Effects of Increased Number of Measurements and Number of Faults.

This article provides a comprehensive analysis of the impact of the increasing number of measurements and the possible increase in the number of faults in multi-constellation Global Navigation Satellite System (GNSS) Receiver Autonomous Integrity Monitoring (RAIM). Residual-based fault detection and integrity monitoring techniques are ubiquitous in linear over-determined sensing systems. An important application is RAIM, as used in multi-constellation GNSS-based positioning. This is a field in which the number of measurements, m, available per epoch is rapidly increasing due to new satellite systems and modernization. Spoofing, multipath, and non-line of sight signals could potentially affect a large number of these signals. This article fully characterizes the impact of measurement faults on the estimation (i.e., position) error, the residual, and their ratio (i.e., the failure mode slope) by analyzing the range space of the measurement matrix and its orthogonal complement. For any fault scenario affecting h measurements, the eigenvalue problem that defines the worst-case fault is expressed and analyzed in terms of these orthogonal subspaces, which enables further analysis. For h>(m-n), where n is the number of estimated variables, it is known that there always exist faults that are undetectable from the residual vector, yielding an infinite value for the failure mode slope. This article uses the range space and its complement to explain: (1) why, for fixed h and n, the failure mode slope decreases with m; (2) why, for a fixed n and m, the failure mode slope increases toward infinity as h increases; (3) why a failure mode slope can become infinite for h≤(m-n). A set of examples demonstrate the results of the paper.

Stochastic Resonance with Parameter Estimation for Enhancing Unknown Compound Fault Detection of Bearings.

Although stochastic resonance (SR) has been widely used to enhance weak fault signatures in machinery and has obtained remarkable achievements in engineering application, the parameter optimization of the existing SR-based methods requires the quantification indicators dependent on prior knowledge of the defects to be detected; for example, the widely used signal-to-noise ratio easily results in a false SR and decreases the detection performance of SR further. These indicators dependent on prior knowledge would not be suitable for real-world fault diagnosis of machinery where their structure parameters are unknown or are not able to be obtained. Therefore, it is necessary for us to design a type of SR method with parameter estimation, and such a method can estimate these parameters of SR adaptively by virtue of the signals to be processed or detected in place of the prior knowledge of the machinery. In this method, the triggered SR condition in second-order nonlinear systems and the synergic relationship among weak periodic signals, background noise and nonlinear systems can be considered to decide parameter estimation for enhancing unknown weak fault characteristics of machinery. Bearing fault experiments were performed to demonstrate the feasibility of the proposed method. The experimental results indicate that the proposed method is able to enhance weak fault characteristics and diagnose weak compound faults of bearings at an early stage without prior knowledge and any quantification indicators, and it presents the same detection performance as the SR methods based on prior knowledge. Furthermore, the proposed method is more simple and less time-consuming than other SR methods based on prior knowledge where a large number of parameters need to be optimized. Moreover, the proposed method is superior to the fast kurtogram method for early fault detection of bearings.