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Register a new userDeep Fault Diagnosis for Rotating Machinery with Scarce Labeled Samples
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Added by
Jing Zhang
Publication date
2019
fields
Electronic Engineering
and research's language is
English
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Early and accurately detecting faults in rotating machinery is crucial for operation safety of the modern manufacturing system. In this paper, we proposed a novel Deep fault diagnosis (DFD) method for rotating machinery with scarce labeled samples. DFD tackles the challenging problem by transferring knowledge from shallow models, which is based on the idea that shallow models trained with different hand-crafted features can reveal the latent prior knowledge and diagnostic expertise and have good generalization ability even with scarce labeled samples. DFD can be divided into three phases. First, a spectrogram of the raw vibration signal is calculated by applying a Short-time Fourier transform (STFT). From those spectrograms, discriminative time-frequency domain features can be extracted and used to form a feature pool. Then, several candidate Support vector machine (SVM) models are trained with different combinations of features in the feature pool with scarce labeled samples. By evaluating the pretrained SVM models on the validation set, the most discriminative features and best-performed SVM models can be selected, which are used to make predictions on the unlabeled samples. The predicted labels reserve the expert knowledge originally carried by the SVM model. They are combined together with the scarce fine labeled samples to form an Augmented training set (ATS). Finally, a novel 2D deep Convolutional neural network (CNN) model is trained on the ATS to learn more discriminative features and a better classifier. Experimental results on two fault diagnosis datasets demonstrate the effectiveness of the proposed DFD, which achieves better performance than SVM models and the vanilla deep CNN model trained on scarce labeled samples. Moreover, it is computationally efficient and is promising for real-time rotating machinery fault diagnosis.
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Fault diagnosis of rotating machinery is an important engineering problem. In recent years, fault diagnosis methods based on the Convolutional Neural Network (CNN) and Recurrent Neural Network (RNN) have been mature, but Transformer has not been widely used in the field of fault diagnosis. To address these deficiencies, a new method based on the Time Series Transformer (TST) is proposed to recognize the fault mode of bearings. In this paper, our contributions include: Firstly, we designed a tokens sequences generation method which can handle data in 1D format, namely time series tokenizer. Then, the TST combining time series tokenizer and Transformer was introduced. Furthermore, the test results on the given dataset show that the proposed method has better fault identification capability than the traditional CNN and RNN models. Secondly, through the experiments, the effect of structural hyperparameters such as subsequence length and embedding dimension on fault diagnosis performance, computational complexity and parameters number of the TST is analyzed in detail. The influence laws of some hyperparameters are obtained. Finally, via t-Distributed Stochastic Neighbor Embedding (t-SNE) dimensionality reduction method, the feature vectors in the embedding space are visualized. On this basis, the working pattern of TST has been explained to a certain extent. Moreover, by analyzing the distribution form of the feature vectors, we find that compared with the traditional CNN and RNN models, the feature vectors extracted by the method in this paper show the best intra-class compactness and inter-class separability. These results further demonstrate the effectiveness of the proposed method.
Data-driven fault diagnosis methods often require abundant labeled examples for each fault type. On the contrary, real-world data is often unlabeled and consists of mostly healthy observations and only few samples of faulty conditions. The lack of labels and fault samples imposes a significant challenge for existing data-driven fault diagnosis methods. In this paper, we aim to overcome this limitation by integrating expert knowledge with domain adaptation in a synthetic-to-real framework for unsupervised fault diagnosis. Motivated by the fact that domain experts often have a relatively good understanding on how different fault types affect healthy signals, in the first step of the proposed framework, a synthetic fault dataset is generated by augmenting real vibration samples of healthy bearings. This synthetic dataset integrates expert knowledge and encodes class information about the faults types. However, models trained solely based on the synthetic data often do not perform well because of the distinct distribution difference between the synthetically generated and real faults. To overcome this domain gap between the synthetic and real data, in the second step of the proposed framework, an imbalance-robust domain adaptation~(DA) approach is proposed to adapt the model from synthetic faults~(source) to the unlabeled real faults~(target) which suffer from severe class imbalance. The framework is evaluated on two unsupervised fault diagnosis cases for bearings, the CWRU laboratory dataset and a real-world wind-turbine dataset. Experimental results demonstrate that the generated faults are effective for encoding fault type information and the domain adaptation is robust against the different levels of class imbalance between faults.
Recent progress on intelligent fault diagnosis has greatly depended on the deep learning and plenty of labeled data. However, the machine often operates with various working conditions or the target task has different distributions with the collected data used for training (we called the domain shift problem). This leads to the deep transfer learning based (DTL-based) intelligent fault diagnosis which attempts to remit this domain shift problem. Besides, the newly collected testing data are usually unlabeled, which results in the subclass DTL-based methods called unsupervised deep transfer learning based (UDTL-based) intelligent fault diagnosis. Although it has achieved huge development in the field of fault diagnosis, a standard and open source code framework and a comparative study for UDTL-based intelligent fault diagnosis are not yet established. In this paper, commonly used UDTL-based algorithms in intelligent fault diagnosis are integrated into a unified testing framework and the framework is tested on five datasets. Extensive experiments are performed to provide a systematically comparative analysis and the benchmark accuracy for more comparable and meaningful further studies. To emphasize the importance and reproducibility of UDTL-based intelligent fault diagnosis, the testing framework with source codes will be released to the research community to facilitate future research. Finally, comparative analysis of results also reveals some open and essential issues in DTL for intelligent fault diagnosis which are rarely studied including transferability of features, influence of backbones, negative transfer, and physical priors. In summary, the released framework and comparative study can serve as an extended interface and the benchmark results to carry out new studies on UDTL-based intelligent fault diagnosis. The code framework is available at https://github.com/ZhaoZhibin/UDTL.
Motor is the most widely used production equipment in industrial field. In order to realize the real-time state monitoring and multi-fault pre-diagnosis of three-phase motor, this paper presents a design of three-phase motor state monitoring and fault diagnosis system based on LabVIEW. The multi-dimensional vibration acceleration, rotational speed, temperature, current and voltage signals of the motor are collected with NI cDAQ acquisition equipment in real time and high speed. At the same time, the model of motor health state and fault state is established. The order analysis algorithm is used to analyze the data at an advanced level, and the diagnosis and classification of different fault types are realized. The system is equipped with multi-channel acquisition, display, analysis and storage. Combined with the current cloud transmission technology, we will back up the data to the cloud to be used by other terminals.
Data-driven fault diagnosis is complicated by unknown fault classes and limited training data from different fault realizations. In these situations, conventional multi-class classification approaches are not suitable for fault diagnosis. One solution is the use of anomaly classifiers that are trained using only nominal data. Anomaly classifiers can be used to detect when a fault occurs but give little information about its root cause. Hybrid fault diagnosis methods combining physically-based models and available training data have shown promising results to improve fault classification performance and identify unknown fault classes. Residual generation using grey-box recurrent neural networks can be used for anomaly classification where physical insights about the monitored system are incorporated into the design of the machine learning algorithm. In this work, an automated residual design is developed using a bipartite graph representation of the system model to design grey-box recurrent neural networks and evaluated using a real industrial case study. Data from an internal combustion engine test bench is used to illustrate the potentials of combining machine learning and model-based fault diagnosis techniques.
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