Traditional artificial methods and intelligence-based methods of classifying and diagnosing various mechanical faults with high accuracy by extracting effective features from vibration data, such as ...support vector machines and back propagation neural networks, have been widely investigated. However, the problems of extracting features automatically without significantly increasing the demand for machinery expertise and maximizing accuracy without overcomplicating machine structure have to date remained unsolved. Therefore, a novel hierarchical learning rate adaptive deep convolution neural network based on an improved algorithm was proposed in this study, and its use to diagnose bearing faults and determine their severity was investigated. To test the effectiveness of the proposed method, an experiment was conducted with bearing-fault data samples obtained from a test rig. The method achieved a satisfactory performance in terms of both fault-pattern recognition and fault-size evaluation. In addition, comparison revealed that the improved algorithm is well suited to the fault-diagnosis model, and that the proposed method is superior to other existing methods.
As a breakthrough in the field of machine fault diagnosis, deep learning has great potential to extract more abstract and discriminative features automatically without much prior knowledge compared ...with other methods, such as the signal processing and analysis-based methods and machine learning methods with shallow architectures. One of the most important aspects in measuring the extracted features is whether they can explore more information of the inputs and avoid redundancy to be representative. Thus, a stacked sparse autoencoder (SAE)-based machine fault diagnosis method is proposed in this paper. The penalty term of the SAE can help mine essential information and avoid redundancy. To help the constructed diagnosis network further mine more abstract and representative high-level features, the collected non-stationary and transient signals are preprocessed with ensemble empirical mode decomposition and autoregressive (AR) models to obtain AR parameters, which are extracted based on the intrinsic mode functions (IMFs) and regarded as the low-level features for the inputs of the proposed diagnosis network. Only the first four IMFs are considered, because fault information is mainly reflected in high-frequency IMFs. Experiments and comparisons are complemented to validate the superiority of the presented diagnosis network. Results fully demonstrate that the stacked SAE-based diagnosis method can extract more discriminative high-level features and has a better performance in rotating machinery fault diagnosis compared with the traditional machine learning methods with shallow architectures.
Remaining useful life (RUL) prediction is necessary for guaranteeing machinery’s safe operation. Among deep learning architectures, convolutional neural network (CNN) has shown achievements in RUL ...prediction because of its strong ability in representation learning. Features from different receptive fields extracted by different sizes of convolution kernels can provide complete information for prognosis. The single size convolution kernel in traditional CNN is difficult to learn comprehensive information from complex signals. Besides, the ability to learn local and global features synchronously is limited to conventional CNN. Thus, a multiscale convolutional neural network (MS-CNN) is introduced to overcome these aforementioned problems. Convolution filters with different dilation rates are integrated to form a dilated convolution block, which can learn features in different receptive fields. Then, several stacked integrated dilated convolution blocks in different depths are concatenated to extract local and global features. The effectiveness of the proposed method is verified by a bearing dataset prepared from the PRONOSTIA platform. The results turn out that the proposed MS-CNN has higher prediction accuracy than many other deep learning-based RUL methods.
Fault diagnosis in rotating machinery is significant to avoid serious accidents; thus, an accurate and timely diagnosis method is necessary. With the breakthrough in deep learning algorithm, some ...intelligent methods, such as deep belief network (DBN) and deep convolution neural network (DCNN), have been developed with satisfactory performances to conduct machinery fault diagnosis. However, only a few of these methods consider properly dealing with noises that exist in practical situations and the denoising methods are in need of extensive professional experiences. Accordingly, rethinking the fault diagnosis method based on deep architectures is essential. Hence, this study proposes an automatic denoising and feature extraction method that inherently considers spatial and temporal correlations. In this study, an integrated deep fault recognizer model based on the stacked denoising autoencoder (SDAE) is applied to both denoise random noises in the raw signals and represent fault features in fault pattern diagnosis for both bearing rolling fault and gearbox fault, and trained in a greedy layer-wise fashion. Finally, the experimental validation demonstrates that the proposed method has better diagnosis accuracy than DBN, particularly in the existing situation of noises with superiority of approximately 7% in fault diagnosis accuracy.
Bearing fault diagnosis plays a vitally important role in practical industrial scenarios. Deep learning-based fault diagnosis methods are usually performed on the hypothesis that the training set and ...test set obey the same probability distribution, which is hard to satisfy under the actual working conditions. This paper proposes a novel multilayer domain adaptation (MLDA) method, which can diagnose the compound fault and single fault of multiple sizes simultaneously. A special designed residual network for the fault diagnosis task is pretrained to extract domain-invariant features. The multikernel maximum mean discrepancy (MK-MMD) and pseudo-label learning are adopted in multiple layers to take both marginal distributions and conditional distributions into consideration. A total of 12 transfer tasks in the fault diagnosis problem are conducted to verify the performance of MLDA. Through the comparisons of different signal processing methods, different parameter settings, and different models, it is proved that the proposed MLDA model can effectively extract domain-invariant features and achieve satisfying results.
In the present study, a novel grinding wheel design method is proposed to design a wheel for grinding different small helical grooves on the existing helical rake faces of the tool. The proposed ...method can be applied to manufacture tools with uneven helical rake face like zigzag-edge twist drills. In the proposed method, the processing of the non-wedge groove is initially converted into a superposition of processing steps of several wedge grooves. Then, based on the simplified non-thickness grinding wheel parametric design and envelop graphic design, the grinding wheel capable of processing small wedge grooves with various specified shapes can be obtained. Moreover, through establishing quantitative evaluation criteria, the determination of design parameters concerning the non-thickness grinding wheel is transmitted into an optimization problem. Finally, helical grooves with trapezoid truncation and wedge truncations are simulated on a virtual five-axis machine tool to verify the effectiveness of the grinding wheel design method.
As a data-driven approach, Deep Learning (DL)-based fault diagnosis methods need to collect the relatively comprehensive data on machine fault types to achieve satisfactory performance. A mechanical ...system may include multiple submachines in the real-world. During condition monitoring of a mechanical system, fault data are distributed in a continuous flow of constantly generated information and new faults will inevitably occur in unconsidered submachines, which are also called machine increments. Therefore, adequately collecting fault data in advance is difficult. Limited by the characteristics of DL, training existing models directly with new fault data of new submachines leads to catastrophic forgetting of old tasks, while the cost of collecting all known data to retrain the models is excessively high. DL-based fault diagnosis methods cannot learn continually and adaptively in dynamic environments. A new Continual Learning Fault Diagnosis method (CLFD) is proposed in this paper to solve a series of fault diagnosis tasks with machine increments. The stability–plasticity dilemma is an intrinsic issue in continual learning. The core of CLFD is the proposed Dual-branch Adaptive Aggregation Residual Network (DAARN). Two types of residual blocks are created in each block layer of DAARN: steady and dynamic blocks. The stability–plasticity dilemma is solved by assigning them with adaptive aggregation weights to balance stability and plasticity, and a bi-level optimization program is used to optimize adaptive aggregation weights and model parameters. In addition, a feature-level knowledge distillation loss function is proposed to further overcome catastrophic forgetting. CLFD is then applied to the fault diagnosis case with machine increments. Results demonstrate that CLFD outperforms other continual learning methods and has satisfactory robustness.
Effective machinery prognostics and health management play a crucial role in ensuring the safe and continuous operation of equipment, and satisfactory characteristics' expression of machine health ...status plays a key role in the ability to diagnose faults with high accuracy. At present, most methods based on signal processing and the shallow learning model rely on artificial feature extraction to identify the machine fault type. In practical applications, however, meaningful health management requires correct recognition of not only the health type but also the fault degree, if any occurs. Such recognition is useful for determining the priority level of mechanical maintenance and minimizing economic losses. Deep learning techniques, such as deep belief network (DBN), have demonstrated great potential in exploring characteristic information from machine status signals. In this paper, an end-to-end fault diagnosis model based on an adaptive DBN optimized by the Nesterov moment (NM) is proposed to extract deep representative features from rotating machinery and recognize bearing fault types and degrees simultaneously. Frequency-domain signals are inputted into the model for feature learning, and NM is introduced to the training process of the DBN model. Individual adaptive learning rate algorithms are then applied to optimize parameter updating. The performance of the proposed method is validated using a self-made bearing fault test platform, and the model is shown to achieve satisfactory convergence and a testing accuracy higher than those obtained from standard DBN and support vector machine.
Mechanical equipment fault detection is critical in industrial applications. Based on vibration signal processing and analysis, the traditional fault diagnosis method relies on rich professional ...knowledge and artificial experience. Achieving accurate feature extraction and fault diagnosis is difficult using such an approach. To learn the characteristics of features from data automatically, a deep learning method is used. A qualitative and quantitative method for rolling bearing faults diagnosis based on an improved convolutional deep belief network (CDBN) is proposed in this study. First, the original vibration signal is converted to the frequency signal with the fast Fourier transform to improve shallow inputs. Second, the Adam optimizer is introduced to accelerate model training and convergence speed. Finally, the model structure is optimized. A multi-layer feature fusion learning structure is put forward wherein the characterization capabilities of each layer can be fully used to improve the generalization ability of the model. In the experimental verification, a laboratory self-made bearing vibration signal dataset was used. The dataset included healthy bearings, nine single faults of different types and sizes, and three different types of composite fault signals. The results of load 0 kN and 1 kN both indicate that the proposed model has better diagnostic accuracy, with an average of 98.15% and 96.15%, compared with the traditional stacked autoencoder, artificial neural network, deep belief network, and standard CDBN. With improved diagnostic accuracy, the proposed model realizes reliable and effective qualitative and quantitative diagnosis of bearing faults.
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