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Intelligent fault diagnosis techniques have replaced time-consuming and unreliable human analysis, increasing the efficiency of fault diagnosis. Deep learning models can improve the accuracy of intelligent fault diagnosis with the help of their multilayer nonlinear mapping ability. This paper proposes a novel method named Deep Convolutional Neural Networks with Wide First-layer Kernels (WDCNN). The proposed method uses raw vibration signals as input (data augmentation is used to generate more inputs), and uses the wide kernels in the first convolutional layer for extracting features and suppressing high frequency noise. Small convolutional kernels in the preceding layers are used for multilayer nonlinear mapping. AdaBN is implemented to improve the domain adaptation ability of the model. The proposed model addresses the problem that currently, the accuracy of CNN applied to fault diagnosis is not very high. WDCNN can not only achieve 100% classification accuracy on normal signals, but also outperform the state-of-the-art DNN model which is based on frequency features under different working load and noisy environment conditions.

Safety and reliability are absolutely important for modern sophisticated systems and technologies. Therefore, malfunction monitoring capabilities are instilled in the system for detection of the incipient faults and anticipation of their impact on the future behavior of the system using fault diagnosis techniques. In particular, state-of-the-art applications rely on the quick and efficient treatment of malfunctions within the equipment/system, resulting in increased production and reduced downtimes. This paper presents developments within Fault Detection and Diagnosis (FDD) methods and reviews of research work in this area. The review presents both traditional model-based and relatively new signal processing-based FDD approaches, with a special consideration paid to artificial intelligence-based FDD methods. Typical steps involved in the design and development of automatic FDD system, including system knowledge representation, data-acquisition and signal processing, fault classification, and maintenance related decision actions, are systematically presented to outline the present status of FDD. Future research trends, challenges and prospective solutions are also highlighted.

Although the effectiveness of machine learning (ML) for machine diagnosis has been widely established, the interpretation of the diagnosis outcomes is still an open issue. Machine learning models behave as black boxes; therefore, the contribution given by each of the selected features to the diagnosis is not transparent to the user. This work is aimed at investigating the capabilities of the SHapley Additive exPlanation (SHAP) to identify the most important features for fault detection and classification in condition monitoring programs for rotating machinery. The authors analyse the case of medium-sized bearings of industrial interest. Namely, vibration data were collected for different health states from the test rig for industrial bearings available at the Mechanical Engineering Laboratory of Politecnico di Torino. The Support Vector Machine (SVM) and k-Nearest Neighbour (kNN) diagnosis models are explained by means of the SHAP. Accuracies higher than 98.5% are achieved for both the models using the SHAP as a criterion for feature selection. It is found that the skewness and the shape factor of the vibration signal have the greatest impact on the models’ outcomes.

Bearing fault diagnosis is imperative for the maintenance, reliability, and durability of rotary machines. It can reduce economical losses by eliminating unexpected downtime in industry due to failure of rotary machines. Though widely investigated in the past couple of decades, continued advancement is still desirable to improve upon existing fault diagnosis techniques. Vibration acceleration signals collected from machine bearings exhibit nonstationary behavior due to variable working conditions and multiple fault severities. In the current work, a two-layered bearing fault diagnosis scheme is proposed for the identification of fault pattern and crack size for a given fault type. A hybrid feature pool is used in combination with sparse stacked autoencoder (SAE)-based deep neural networks (DNNs) to perform effective diagnosis of bearing faults of multiple severities. The hybrid feature pool can extract more discriminating information from the raw vibration signals, to overcome the nonstationary behavior of the signals caused by multiple crack sizes. More discriminating information helps the subsequent classifier to effectively classify data into the respective classes. The results indicate that the proposed scheme provides satisfactory performance in diagnosing bearing defects of multiple severities. Moreover, the results also demonstrate that the proposed model outperforms other state-of-the-art algorithms, i.e., support vector machines (SVMs) and backpropagation neural networks (BPNNs).

Intelligent fault diagnosis methods based on signal analysis have been widely used for bearing fault diagnosis. These methods use a pre-determined transformation (such as empirical mode decomposition, fast Fourier transform, discrete wavelet transform) to convert time-series signals into frequency domain signals, the performance of dignostic system is significantly rely on the extracted features. However, extracting signal characteristic is fairly time consuming and depends on specialized signal processing knowledge. Although some studies have developed highly accurate algorithms, the diagnostic results rely heavily on large data sets and unreliable human analysis. This study proposes an automatic feature learning neural network that utilizes raw vibration signals as inputs, and uses two convolutional neural networks with different kernel sizes to automatically extract different frequency signal characteristics from raw data. Then long short-term memory was used to identify the fault type according to learned features. The data is down-sampled before inputting into the network, greatly reducing the number of parameters. The experiment shows that the proposed method can not only achieve 98.46% average accuracy, exceeding some state-of-the-art intelligent algorithms based on prior knowledge and having better performance in noisy environments.

Fault diagnostics and prognostics are important topics both in practice and research. There is an intense pressure on industrial plants to continue reducing unscheduled downtime, performance degradation, and safety hazards, which requires detecting and recovering potential faults in its early stages. Intelligent fault diagnosis is a promising tool due to its ability to rapidly and efficiently processing collected signals and providing accurate diagnosis results. Although many studies have developed machine leaning (M.L) and deep learning (D.L) algorithms for detecting the bearing fault, the results have generally been limited to relatively small train and test datasets and the input data has been manipulated (selective features used) to reach high accuracy. In this work, the raw data, collected from accelerometers (time-domain features) are taken as the input of a novel temporal sequence prediction algorithm to present an end-to-end method for fault detection. We use equivalent temporal sequences as the input of a novel Convolutional Long-Short-Term-Memory Recurrent Neural Network (CRNN) to detect the bearing fault with the highest accuracy in the shortest possible time. The method can reach the highest accuracy in the literature, to the best knowledge of the authors of the present paper, voiding any sort of pre-processing or manipulation of the input data. Effectiveness and feasibility of the fault diagnosis method are validated by applying it to two commonly used benchmark real vibration datasets and comparing the result with the other intelligent fault diagnosis methods.

Efficient fault diagnosis of electrical and mechanical anomalies in induction motors (IMs) is challenging but necessary to ensure safety and economical operation in industries. Research has shown that bearing faults are the most frequently occurring faults in IMs. The vibration signals carry rich information about bearing health conditions and are commonly utilized for fault diagnosis in bearings. However, collecting these signals is expensive and sometimes impractical because it requires the use of external sensors. The external sensors demand enough space and are difficult to install in inaccessible sites. To overcome these disadvantages, motor current signal-based bearing fault diagnosis methods offer an attractive solution. As such, this paper proposes a hybrid motor-current data-driven approach that utilizes statistical features, genetic algorithm (GA) and machine learning models for bearing fault diagnosis. First, the statistical features are extracted from the motor current signals. Second, the GA is utilized to reduce the number of features and select the most important ones from the feature database. Finally, three different classification algorithms namely KNN, decision tree, and random forest, are trained and tested using these features in order to evaluate the bearing faults. This combination of techniques increases the accuracy and reduces the computational complexity. The experimental results show that the three classifiers achieve an accuracy of more than 97%. In addition, the evaluation parameters such as precision, F1-score, sensitivity, and specificity show better performance. Finally, to validate the efficiency of the proposed model, it is compared with some recently adopted techniques. The comparison results demonstrate that the suggested technique is promising for diagnosis of IM bearing faults.

With the rapid development and increasing energy production capacity of high-power wind turbines, a corresponding increase in maintenance requirements has been observed. Reducing the failure rate of wind turbines is a critical objective, alongside decreasing affiliated operation and maintenance costs. This review focuses on the status monitoring, fault diagnosis, fault prediction, and status evaluation of wind turbines. The early fault diagnosis of wind turbines is explored with regard to existing condition monitoring technology. Moreover, the current mathematics-based fault diagnosis and smart fault diagnosis technologies are further explored. Through comprehensive investigation, this paper summarizes the research status of wind turbine fault prediction and complete machine status evaluation, conclusively presenting relevant research points and trends in the fault diagnosis, fault prediction, and status assessment of high-power wind turbines.

Process fault detection and diagnosis (FDD) is a predominant task to ensure product quality and process reliability in modern industrial systems. Those traditional FDD techniques are largely based on diagnostic experience. These methods have met significant challenges with immense expansion of plant scale and large numbers of process variables. Recently, deep learning has become the newest trends in process control. The upsurge of deep neural networks (DNNs) in leaning highly discriminative features from complicated process data has provided practitioners with effective process monitoring tools. This paper is to present a review and full developing route of deep learning-based FDD in complex process industries. Firstly, the nature of traditional data projection-based and machine learning-based FDD methods is discussed in process FDD. Secondly, the characteristics of deep learning and their applications in process FDD are illustrated. Thirdly, these typical deep learning techniques, e.g., transfer learning, generative adversarial network, capsule network, graph neural network, are presented for process FDD. These DNNs will effectively solve these problems of fault detection, fault classification, and fault isolation in process. Finally, the developing route of DNN-based process FDD techniques is highlighted for future work.

Artificial intelligence (AI)-based rotor fault diagnosis (RFD) poses a variety of challenges to the prognostics and health management (PHM) of the Industry 4.0 revolution. Rotor faults have drawn more attention from the AI research community in terms of utilizing fault-specific characteristics in its feature engineering, compared to any other rotating machinery faults. While the rotor faults, specifically structural rotor faults (SRF), have proven to be the root cause of most of the rotating machinery issues, the research in this field largely revolves around bearing and gear faults. Within this scenario, this paper is the first of its kind to attempt to review and define the role of AI in RFD and provides an all-encompassing review of rotor faults for the researchers and academics. In addition, this study is unique in three ways: (i) it emphasizes the use of fault-specific characteristic features with AI, (ii) it is grounded in fault-wise analysis rather than component-wise analysis with appropriate fault categorization, and (iii) it portrays the current research and analysis in accordance with different phases of an AI-based RFD framework. Finally, the section on future research directions is aimed at bridging the gap between a laboratory-based solution and a real-world industrial solution for RFD.