Novel Fault Diagnosis of a Conveyor Belt Mis-Tracking via Motor Current Signature Analysis.

For the first time ever worldwide, this paper proposes, investigates, and validates, by multiple experiments, a new online automatic diagnostic technology for the belt mis-tracking of belt conveyor systems based on motor current signature analysis (MCSA). Three diagnostic technologies were investigated, experimentally evaluated, and compared for conveyor belt mis-tracking diagnosis. The proposed technologies are based on three higher-order spectral diagnostic features: bicoherence, tricoherence, and the cross-correlation of spectral moduli of order 3 (CCSM3). The investigation of the proposed technologies via comprehensive experiments has shown that technology based on the CCSM3 is highly effective for diagnosing a conveyor belt mis-tracking via MCSA.

Novel Investigation of Higher Order Spectral Technologies for Fault Diagnosis of Motor-Based Rotating Machinery.

In the last decade, research centered around the fault diagnosis of rotating machinery using non-contact techniques has been significantly on the rise. For the first time worldwide, innovative techniques for the diagnosis of rotating machinery, based on electrical motors, including generic, nonlinear, higher-order cross-correlations of spectral moduli of the third and fourth order (CCSM3 and CCSM4, respectively), have been comprehensively validated by modeling and experiments. The existing higher-order cross-correlations of complex spectra are not sufficiently effective for the fault diagnosis of rotating machinery. The novel technology CCSM3 was comprehensively experimentally validated for induction motor bearing diagnosis via motor current signals. Experimental results, provided by the validated technology, confirmed high overall probabilities of correct diagnosis for bearings at early stages of damage development. The novel diagnosis technologies were compared with existing diagnosis technologies, based on triple and fourth cross-correlations of the complex spectra. The comprehensive validation and comparison of the novel cross-correlation technologies confirmed an important non-traditional novel outcome: the technologies based on cross-correlations of spectral moduli were more effective for damage diagnosis than the technologies based on cross-correlations of the complex spectra. Experimental and simulation validations confirmed a high probability of correct diagnosis via the CCSM at the early stage of fault development. The average total probability of incorrect diagnosis for the CCSM3 for all experimental results of 8 tested bearings, estimated via 6528 diagnostic features, was 1.475%. The effectiveness gains in the total probability of incorrect diagnosis for the CCSM3 in comparison with the CCCS3 were 26.8 for the experimental validation and 18.9 for the simulation validation. The effectiveness gains in the Fisher criterion for the CCSM3 in comparison with the CCCS3 were 50.7 for the simulation validation and 104.7 for the experimental validation.

Novel Vision Monitoring Method Based on Multi Light Points for Space-Time Analysis of Overhead Contact Line Displacements.

The article presents an innovative vision monitoring method of overhead contact line (OCL) displacement, which utilizes a set of LED light points installed along it. A light point is an, LED fed from a battery. Displacements of the LED points, recorded by a camera, are interpreted as a change of OCL shape in time and space. The vision system comprises a camera, properly situated with respect to the OCL, which is capable of capturing a dozen light points in its field of view. The monitoring system can be scaled by increasing the number of LED points and video cameras; thus, this method can be used for monitoring the motion of other large-size objects (e.g., several hundred meters). The applied method has made it possible to obtain the following novel results: vibration damping in a contact wire is nonlinear by nature and its intensity depends on the wire vibration amplitude; the natural frequency of contact wire vibration varies, and it is a function of vibration amplitude; the natural frequency of contact wire vibration also depends on the wire temperature. The proposed method can be used to monitor the uplift of contact and messenger wires in laboratory conditions, or for experimental OCL testing, as well as for verifying simulation models of OCL.

Novel Diagnosis Technologies for a Lack of Oil Lubrication in Gearmotor Systems, Based on Motor Current Signature Analysis.

Due to the wide use of gearmotor systems in industry, many diagnostic techniques have been developed/employed to prevent their failures. An insufficient lubrication of gearboxes of these machines could shorten their life and lead to catastrophic failures and losses, making it important to ensure a required lubrication level. For the first time in worldwide terms, this paper proposed to diagnose a lack of gearbox oil lubrication using motor current signature analysis (MCSA). This study proposed, investigated, and experimentally validated two new technologies to diagnose a lack of lubrication of gear motor systems based on MCSA. Two new diagnostic features were extracted from the current signals of a three-phase induction motor. The effectiveness of the proposed technologies was evaluated for different gear lubrication levels and was compared for three phases of motor current signals and for a case of averaging the proposed diagnostic features over three phases. The results confirmed a high effectiveness of the proposed technologies for diagnosing a lack of oil lubrication in gearmotor systems. Other contributions were as follows: (i) it was shown for the first time in worldwide terms, that the motor current nonlinearity level increases with the reduction of the sgearbox oil level; (ii) novel experimental validations of the proposed two diagnostic technologies via comprehensive experimental trials (iii) novel experimental comparisons of the diagnosis effectiveness of the proposed two diagnostic technologies.

A Fuzzy Fusion Rotating Machinery Fault Diagnosis Framework Based on the Enhancement Deep Convolutional Neural Networks.

Some artificial intelligence algorithms have gained much attention in the rotating machinery fault diagnosis due to their robust nonlinear regression properties. In addition, existing deep learning algorithms are usually dependent on single signal features, which would lead to the loss of some information or incomplete use of the information in the signal. To address this problem, three kinds of popular signal processing methods, including Fast Fourier Transform (FFT), Short-Time Fourier Transform (STFT) and directly slicing one-dimensional data into the two-dimensional matrix, are used to create four different datasets from raw vibration signal as the input data of four enhancement Convolutional Neural Networks (CNN) models. Then, a fuzzy fusion strategy is used to fuse the output of four CNN models that could analyze the importance of each classifier and explore the interaction index between each classifier, which is different from conventional fusion strategies. To show the performance of the proposed model, an artificial fault bearing dataset and a real-world bearing dataset are used to test the feature extraction capability of the model. The good anti-noise and interpretation characteristics of the proposed method are demonstrated as well.

Novel Prediction of Diagnosis Effectiveness for Adaptation of the Spectral Kurtosis Technology to Varying Operating Conditions.

In this paper, two novel consistency vectors are proposed, which when combined with appropriate machine learning algorithms, can be used to adapt the Spectral Kurtosis technology for optimum gearbox damage diagnosis in varying operating conditions. Much of the existing research in the field is limited to test apparatus run in constant and carefully controlled operating conditions, and the authors have previously publicised that the Spectral Kurtosis technology requires adaptation to achieve the highest possible probabilities of correct diagnosis when a gearbox is run in non-stationary conditions of speed and load. However, the authors' previous adaptation has been computationally heavy using a brute-force approach unsuited to online use, and therefore, created the requirement to develop these two newly proposed vectors and allow computationally lighter techniques more suited to online condition monitoring. The new vectors are demonstrated and experimentally validated on vibration data collected from a gearbox run in multiple combinations of operating conditions; for the first time, the two consistency vectors are used to predict diagnosis effectiveness, with the comparison and proof of relative gains between the traditional and novel techniques discussed. Consistency calculations are computationally light and thus, many combinations of Spectral Kurtosis technology parameters can be evaluated on a dataset in a very short time. This study shows that machine learning can predict the total probability of correct diagnosis from the consistency values and this can quickly provide pre-adaptation/prediction of optimum Spectral Kurtosis technology parameters for a dataset. The full adaptation and damage evaluation process, which is computationally heavier, can then be undertaken on a much lower number of combinations of Spectral Kurtosis resolution and threshold.

Novel Method for Vibration Sensor-Based Instantaneous Defect Frequency Estimation for Rolling Bearings Under Non-Stationary Conditions.

It is proposed a novel instantaneous frequency estimation technology, multi-generalized demodulation transform, for non-stationary signals, whose true time variations of instantaneous frequencies are unknown and difficult to extract from the time-frequency representation due to essentially noisy environment. Theoretical bases of the novel instantaneous frequency estimation technology are created. The main innovations are summarized as: (a) novel instantaneous frequency estimation technology, multi-generalized demodulation transform, is proposed, (b) novel instantaneous frequency estimation results, obtained by simulation, for four types of amplitude and frequency modulated non-stationary single and multicomponent signals under strong background noise (signal to noise ratio is -5 dB), and (c) novel experimental instantaneous frequency estimation results for defect frequency of rolling bearings for multiple defect frequency harmonics, using the proposed technology in non-stationary conditions and in conditions of different levels of noise interference, including a strong noise interference. Quantitative instantaneous frequency estimation errors are employed to evaluate performance of the proposed IF estimation technology. Simulation and experimental estimation results show high effectiveness of the proposed estimation technology.

Novel Higher-Order Spectral Cross-Correlation Technologies for Vibration Sensor-Based Diagnosis of Gearboxes.

Novel vibration sensor-based diagnostic technologies, built on the higher order wavelet spectral cross-correlation (WSC), are proposed, investigated and applied to gearbox vibration diagnosis for the first time in worldwide terms. The proposed WSC-based technologies do not feature any constrains in selection of signal spectral components, relations between which are analysed. That is a radical improvement in comparison with the higher-order spectra (HOS). The WSC technologies are applied for an experimental diagnosis of a local gear tooth fault of a helical gearbox that is developed during a long duration gearbox endurance test. Differences between the applied technologies and advantages of the novel WSC approach over the classical HOS are explained in detail. Superiority of the WSC technologies is justified by high validity comprehensive experimental comparison with the HOS technologies: i.e., the wavelet bicoherence and the wavelet tricoherence.