Expert Experience and Data-Driven Based Hybrid Fault Diagnosis for High-SpeedWire Rod Finishing Mills

The reliable operation of high-speed wire rod finishing mills is crucial in the steel production enterprise.As complex system-level equipment,it is difficult for high-speed wire rod finishing mills to realize fault location and real-time monitoring.To solve the above problems,an expert experience and data-driven-based hybrid fault diagnosis method for high-speed wire rod finishing mills is proposed in this paper.First,based on its mechanical structure,time and frequency domain analysis are improved in fault feature extraction.The approach of combining virtual value,peak value with kurtosis value index,is adopted in time domain analysis.Speed adjustment and side frequency analysis are proposed in frequency domain analysis to obtain accurate component characteristic frequency and its corresponding sideband.Then,according to time and frequency domain characteristics,fault location based on expert experience is proposed to get an accurate fault result.Finally,the proposed method is implemented in the equipment intelligent diagnosis system.By taking an equipment fault on site,for example,the effectiveness of the proposed method is illustrated in the system.

Dynamic Vision Enabled Contactless Cross-Domain Machine Fault Diagnosis With Neuromorphic Computing

Dear Editor,This letter presents a novel dynamic vision enabled contactless cross-domain fault diagnosis method with neuromorphic computing.The event-based camera is adopted to capture the machine vibration states in the perspective of vision.

A novel multi-resolution network for the open-circuit faults diagnosis of automatic ramming drive system

The open-circuit fault is one of the most common faults of the automatic ramming drive system(ARDS),and it can be categorized into the open-phase faults of Permanent Magnet Synchronous Motor(PMSM)and the open-circuit faults of Voltage Source Inverter(VSI). The stator current serves as a common indicator for detecting open-circuit faults. Due to the identical changes of the stator current between the open-phase faults in the PMSM and failures of double switches within the same leg of the VSI, this paper utilizes the zero-sequence voltage component as an additional diagnostic criterion to differentiate them.Considering the variable conditions and substantial noise of the ARDS, a novel Multi-resolution Network(Mr Net) is proposed, which can extract multi-resolution perceptual information and enhance robustness to the noise. Meanwhile, a feature weighted layer is introduced to allocate higher weights to characteristics situated near the feature frequency. Both simulation and experiment results validate that the proposed fault diagnosis method can diagnose 25 types of open-circuit faults and achieve more than98.28% diagnostic accuracy. In addition, the experiment results also demonstrate that Mr Net has the capability of diagnosing the fault types accurately under the interference of noise signals(Laplace noise and Gaussian noise).

Uncertainty-Aware Deep Learning: A Promising Tool for Trustworthy Fault Diagnosis

Recently,intelligent fault diagnosis based on deep learning has been extensively investigated,exhibiting state-of-the-art performance.However,the deep learning model is often not truly trusted by users due to the lack of interpretability of“black box”,which limits its deployment in safety-critical applications.A trusted fault diagnosis system requires that the faults can be accurately diagnosed in most cases,and the human in the deci-sion-making loop can be found to deal with the abnormal situa-tion when the models fail.In this paper,we explore a simplified method for quantifying both aleatoric and epistemic uncertainty in deterministic networks,called SAEU.In SAEU,Multivariate Gaussian distribution is employed in the deep architecture to compensate for the shortcomings of complexity and applicability of Bayesian neural networks.Based on the SAEU,we propose a unified uncertainty-aware deep learning framework(UU-DLF)to realize the grand vision of trustworthy fault diagnosis.Moreover,our UU-DLF effectively embodies the idea of“humans in the loop”,which not only allows for manual intervention in abnor-mal situations of diagnostic models,but also makes correspond-ing improvements on existing models based on traceability analy-sis.Finally,two experiments conducted on the gearbox and aero-engine bevel gears are used to demonstrate the effectiveness of UU-DLF and explore the effective reasons behind.

Bearing Fault Diagnosis Based on Deep Discriminative Adversarial Domain Adaptation Neural Networks

Intelligent diagnosis driven by big data for mechanical fault is an important means to ensure the safe operation ofequipment. In these methods, deep learning-based machinery fault diagnosis approaches have received increasingattention and achieved some results. It might lead to insufficient performance for using transfer learning alone andcause misclassification of target samples for domain bias when building deep models to learn domain-invariantfeatures. To address the above problems, a deep discriminative adversarial domain adaptation neural networkfor the bearing fault diagnosis model is proposed (DDADAN). In this method, the raw vibration data are firstlyconverted into frequency domain data by Fast Fourier Transform, and an improved deep convolutional neuralnetwork with wide first-layer kernels is used as a feature extractor to extract deep fault features. Then, domaininvariant features are learned from the fault data with correlation alignment-based domain adversarial training.Furthermore, to enhance the discriminative property of features, discriminative feature learning is embeddedinto this network to make the features compact, as well as separable between classes within the class. Finally, theperformance and anti-noise capability of the proposedmethod are evaluated using two sets of bearing fault datasets.The results demonstrate that the proposed method is capable of handling domain offset caused by differentworkingconditions and maintaining more than 97.53% accuracy on various transfer tasks. Furthermore, the proposedmethod can achieve high diagnostic accuracy under varying noise levels.

Selective and Adaptive Incremental Transfer Learning with Multiple Datasets for Machine Fault Diagnosis

The visions of Industry 4.0 and 5.0 have reinforced the industrial environment.They have also made artificial intelligence incorporated as a major facilitator.Diagnosing machine faults has become a solid foundation for automatically recognizing machine failure,and thus timely maintenance can ensure safe operations.Transfer learning is a promising solution that can enhance the machine fault diagnosis model by borrowing pre-trained knowledge from the source model and applying it to the target model,which typically involves two datasets.In response to the availability of multiple datasets,this paper proposes using selective and adaptive incremental transfer learning(SA-ITL),which fuses three algorithms,namely,the hybrid selective algorithm,the transferability enhancement algorithm,and the incremental transfer learning algorithm.It is a selective algorithm that enables selecting and ordering appropriate datasets for transfer learning and selecting useful knowledge to avoid negative transfer.The algorithm also adaptively adjusts the portion of training data to balance the learning rate and training time.The proposed algorithm is evaluated and analyzed using ten benchmark datasets.Compared with other algorithms from existing works,SA-ITL improves the accuracy of all datasets.Ablation studies present the accuracy enhancements of the SA-ITL,including the hybrid selective algorithm(1.22%-3.82%),transferability enhancement algorithm(1.91%-4.15%),and incremental transfer learning algorithm(0.605%-2.68%).These also show the benefits of enhancing the target model with heterogeneous image datasets that widen the range of domain selection between source and target domains.

Label Recovery and Trajectory Designable Network for Transfer Fault Diagnosis of Machines With Incorrect Annotation

The success of deep transfer learning in fault diagnosis is attributed to the collection of high-quality labeled data from the source domain.However,in engineering scenarios,achieving such high-quality label annotation is difficult and expensive.The incorrect label annotation produces two negative effects:1)the complex decision boundary of diagnosis models lowers the generalization performance on the target domain,and2)the distribution of target domain samples becomes misaligned with the false-labeled samples.To overcome these negative effects,this article proposes a solution called the label recovery and trajectory designable network(LRTDN).LRTDN consists of three parts.First,a residual network with dual classifiers is to learn features from cross-domain samples.Second,an annotation check module is constructed to generate a label anomaly indicator that could modify the abnormal labels of false-labeled samples in the source domain.With the training of relabeled samples,the complexity of diagnosis model is reduced via semi-supervised learning.Third,the adaptation trajectories are designed for sample distributions across domains.This ensures that the target domain samples are only adapted with the pure-labeled samples.The LRTDN is verified by two case studies,in which the diagnosis knowledge of bearings is transferred across different working conditions as well as different yet related machines.The results show that LRTDN offers a high diagnosis accuracy even in the presence of incorrect annotation.

Intelligent Fault Diagnosis Method of Rolling Bearings Based on Transfer Residual Swin Transformer with Shifted Windows

Due to their robust learning and expression ability for complex features,the deep learning(DL)model plays a vital role in bearing fault diagnosis.However,since there are fewer labeled samples in fault diagnosis,the depth of DL models in fault diagnosis is generally shallower than that of DL models in other fields,which limits the diagnostic performance.To solve this problem,a novel transfer residual Swin Transformer(RST)is proposed for rolling bearings in this paper.RST has 24 residual self-attention layers,which use the hierarchical design and the shifted window-based residual self-attention.Combined with transfer learning techniques,the transfer RST model uses pre-trained parameters from ImageNet.A new end-to-end method for fault diagnosis based on deep transfer RST is proposed.Firstly,wavelet transform transforms the vibration signal into a wavelet time-frequency diagram.The signal’s time-frequency domain representation can be represented simultaneously.Secondly,the wavelet time-frequency diagram is the input of the RST model to obtain the fault type.Finally,our method is verified on public and self-built datasets.Experimental results show the superior performance of our method by comparing it with a shallow neural network.

Fault Diagnosis Method of Rolling Bearing Based on ESGMD-CC and AFSA-ELM

Incomplete fault signal characteristics and ease of noise contamination are issues with the current rolling bearing early fault diagnostic methods,making it challenging to ensure the fault diagnosis accuracy and reliability.A novel approach integrating enhanced Symplectic geometry mode decomposition with cosine difference limitation and calculus operator(ESGMD-CC)and artificial fish swarm algorithm(AFSA)optimized extreme learning machine(ELM)is proposed in this paper to enhance the extraction capability of fault features and thus improve the accuracy of fault diagnosis.Firstly,SGMD decomposes the raw vibration signal into multiple Symplectic geometry components(SGCs).Secondly,the iterations are reset by the cosine difference limitation to effectively separate the redundant components from the representative components.Additionally,the calculus operator is performed to strengthen weak fault features and make them easier to extract,and the singular value decomposition(SVD)weighted by power spectrum entropy(PSE)can be utilized as the sample feature representation.Finally,AFSA iteratively optimized ELM is adopted as the optimized classifier for fault identification.The superior performance of the proposed method has been validated by various experiments.

Optical Fibre Communication Feature Analysis and Small Sample Fault Diagnosis Based on VMD-FE and Fuzzy Clustering

To solve the problems of a few optical fibre line fault samples and the inefficiency of manual communication optical fibre fault diagnosis,this paper proposes a communication optical fibre fault diagnosis model based on variational modal decomposition(VMD),fuzzy entropy(FE)and fuzzy clustering(FC).Firstly,based on the OTDR curve data collected in the field,VMD is used to extract the different modal components(IMF)of the original signal and calculate the fuzzy entropy(FE)values of different components to characterize the subtle differences between them.The fuzzy entropy of each curve is used as the feature vector,which in turn constructs the communication optical fibre feature vector matrix,and the fuzzy clustering algorithm is used to achieve fault diagnosis of faulty optical fibre.The VMD-FE combination can extract subtle differences in features,and the fuzzy clustering algorithm does not require sample training.The experimental results show that the model in this paper has high accuracy and is relevant to the maintenance of communication optical fibre when compared with existing feature extraction models and traditional machine learning models.

Research on Instantaneous Angular Speed Signal Separation Method for Planetary Gear Fault Diagnosis

Planetary gear train is a critical transmission component in large equipment such as helicopters and wind turbines. Conducting damage perception of planetary gear trains is of great significance for the safe operation of equipment. Existing methods for damage perception of planetary gear trains mainly rely on linear vibration analysis. However, these methods based on linear vibration signal analysis face challenges such as rich vibration sources, complex signal coupling and modulation mechanisms, significant influence of transmission paths, and difficulties in separating damage information. This paper proposes a method for separating instantaneous angular speed (IAS) signals for planetary gear fault diagnosis. Firstly, this method obtains encoder pulse signals through a built-in encoder. Based on this, it calculates the IAS signals using the Hilbert transform, and obtains the time-domain synchronous average signal of the IAS of the planetary gear through time-domain synchronous averaging technology, thus realizing the fault diagnosis of the planetary gear train. Experimental results validate the effectiveness of the calculated IAS signals, demonstrating that the time-domain synchronous averaging technology can highlight impact characteristics, effectively separate and extract fault impacts, greatly reduce the testing cost of experiments, and provide an effective tool for the fault diagnosis of planetary gear trains.

Research on Rotating Machinery Fault Diagnosis Based on Improved Multi-target Domain Adversarial Network

Aiming at the problems of low efficiency,poor anti-noise and robustness of transfer learning model in intelligent fault diagnosis of rotating machinery,a new method of intelligent fault diagnosis of rotating machinery based on single source and multi-target domain adversarial network model(WDMACN)and Gram Angle Product field(GAPF)was proposed.Firstly,the original one-dimensional vibration signal is preprocessed using GAPF to generate the image data including all time series.Secondly,the residual network is used to extract data features,and the features of the target domain without labels are pseudo-labeled,and the transferable features among the feature extractors are shared through the depth parameter,and the feature extractors of the multi-target domain are updated anatomically to generate the features that the discriminator cannot distinguish.The modelt through adversarial domain adaptation,thus achieving fault classification.Finally,a large number of validations were carried out on the bearing data set of Case Western Reserve University(CWRU)and the gear data.The results show that the proposed method can greatly improve the diagnostic efficiency of the model,and has good noise resistance and generalization.

Denoising Fault-Aware Wavelet Network:A Signal Processing Informed Neural Network for Fault Diagnosis

Deep learning(DL) is progressively popular as a viable alternative to traditional signal processing(SP) based methods for fault diagnosis. However, the lack of explainability makes DL-based fault diagnosis methods difficult to be trusted and understood by industrial users. In addition, the extraction of weak fault features from signals with heavy noise is imperative in industrial applications. To address these limitations, inspired by the Filterbank-Feature-Decision methodology, we propose a new Signal Processing Informed Neural Network(SPINN) framework by embedding SP knowledge into the DL model. As one of the practical implementations for SPINN, a denoising fault-aware wavelet network(DFAWNet) is developed, which consists of fused wavelet convolution(FWConv), dynamic hard thresholding(DHT),index-based soft filtering(ISF), and a classifier. Taking advantage of wavelet transform, FWConv extracts multiscale features while learning wavelet scales and selecting important wavelet bases automatically;DHT dynamically eliminates noise-related components via point-wise hard thresholding;inspired by index-based filtering, ISF optimizes and selects optimal filters for diagnostic feature extraction. It’s worth noting that SPINN may be readily applied to different deep learning networks by simply adding filterbank and feature modules in front. Experiments results demonstrate a significant diagnostic performance improvement over other explainable or denoising deep learning networks. The corresponding code is available at https://github. com/alber tszg/DFAWn et.

Distributed fault diagnosis observer for multi-agent system against actuator and sensor faults

Component failures can cause multi-agent system(MAS)performance degradation and even disasters,which provokes the demand of the fault diagnosis method.A distributed sliding mode observer-based fault diagnosis method for MAS is developed in presence of actuator and sensor faults.Firstly,the actuator and sensor faults are extended to the system state,and the system is transformed into a descriptor system form.Then,a sliding mode-based distributed unknown input observer is proposed to estimate the extended state.Furthermore,adaptive laws are introduced to adjust the observer parameters.Finally,the effectiveness of the proposed method is demonstrated with numerical simulations.

Construction of fault diagnosis system for control rod drive mechanism based on knowledge graph and Bayesian inference

Knowledge graph technology has distinct advantages in terms of fault diagnosis.In this study,the control rod drive mechanism(CRDM)of the liquid fuel thorium molten salt reactor(TMSR-LF1)was taken as the research object,and a fault diagnosis system was proposed based on knowledge graph.The subject–relation–object triples are defined based on CRDM unstructured data,including design specification,operation and maintenance manual,alarm list,and other forms of expert experience.In this study,we constructed a fault event ontology model to label the entity and relationship involved in the corpus of CRDM fault events.A three-layer robustly optimized bidirectional encoder representation from transformers(RBT3)pre-training approach combined with a text convolutional neural network(TextCNN)was introduced to facilitate the application of the constructed CRDM fault diagnosis graph database for fault query.The RBT3-TextCNN model along with the Jieba tool is proposed for extracting entities and recognizing the fault query intent simultaneously.Experiments on the dataset collected from TMSR-LF1 CRDM fault diagnosis unstructured data demonstrate that this model has the potential to improve the effect of intent recognition and entity extraction.Additionally,a fault alarm monitoring module was developed based on WebSocket protocol to deliver detailed information about the appeared fault to the operator automatically.Furthermore,the Bayesian inference method combined with the variable elimination algorithm was proposed to enable the development of a relatively intelligent and reliable fault diagnosis system.Finally,a CRDM fault diagnosis Web interface integrated with graph data visualization was constructed,making the CRDM fault diagnosis process intuitive and effective.

A Novel Belief Rule-Based Fault Diagnosis Method with Interpretability

Fault diagnosis plays an irreplaceable role in the normal operation of equipment.A fault diagnosis model is often required to be interpretable for increasing the trust between humans and the model.Due to the understandable knowledge expression and transparent reasoning process,the belief rule base(BRB)has extensive applications as an interpretable expert system in fault diagnosis.Optimization is an effective means to weaken the subjectivity of experts in BRB,where the interpretability of BRB may be weakened.Hence,to obtain a credible result,the weakening factors of interpretability in the BRB-based fault diagnosis model are firstly analyzed,which are manifested in deviation from the initial judgement of experts and over-optimization of parameters.For these two factors,three indexes are proposed,namely the consistency index of rules,consistency index of the rule base and over-optimization index,tomeasure the interpretability of the optimizedmodel.Considering both the accuracy and interpretability of amodel,an improved coordinate ascent(I-CA)algorithmis proposed to fine-tune the parameters of the fault diagnosis model based on BRB.In I-CA,the algorithm combined with the advance and retreat method and the golden section method is employed to be one-dimensional search algorithm.Furthermore,the random optimization sequence and adaptive step size are proposed to improve the accuracy of the model.Finally,a case study of fault diagnosis in aerospace relays based on BRB is carried out to verify the effectiveness of the proposed method.

Fault Diagnosis of Power Electronic Circuits Based on Adaptive Simulated Annealing Particle Swarm Optimization

In the field of energy conversion,the increasing attention on power electronic equipment is fault detection and diagnosis.A power electronic circuit is an essential part of a power electronic system.The state of its internal components affects the performance of the system.The stability and reliability of an energy system can be improved by studying the fault diagnosis of power electronic circuits.Therefore,an algorithm based on adaptive simulated annealing particle swarm optimization(ASAPSO)was used in the present study to optimize a backpropagation(BP)neural network employed for the online fault diagnosis of a power electronic circuit.We built a circuit simulation model in MATLAB to obtain its DC output voltage.Using Fourier analysis,we extracted fault features.These were normalized as training samples and input to an unoptimized BP neural network and BP neural networks optimized by particle swarm optimization(PSO)and the ASAPSO algorithm.The accuracy of fault diagnosis was compared for the three networks.The simulation results demonstrate that a BP neural network optimized with the ASAPSO algorithm has higher fault diagnosis accuracy,better reliability,and adaptability and can more effectively diagnose and locate faults in power electronic circuits.

Power Transformer Fault Diagnosis Using Random Forest and Optimized Kernel Extreme Learning Machine

Power transformer is one of the most crucial devices in power grid.It is significant to determine incipient faults of power transformers fast and accurately.Input features play critical roles in fault diagnosis accuracy.In order to further improve the fault diagnosis performance of power trans-formers,a random forest feature selection method coupled with optimized kernel extreme learning machine is presented in this study.Firstly,the random forest feature selection approach is adopted to rank 42 related input features derived from gas concentration,gas ratio and energy-weighted dissolved gas analysis.Afterwards,a kernel extreme learning machine tuned by the Aquila optimization algorithm is implemented to adjust crucial parameters and select the optimal feature subsets.The diagnosis accuracy is used to assess the fault diagnosis capability of concerned feature subsets.Finally,the optimal feature subsets are applied to establish fault diagnosis model.According to the experimental results based on two public datasets and comparison with 5 conventional approaches,it can be seen that the average accuracy of the pro-posed method is up to 94.5%,which is superior to that of other conventional approaches.Fault diagnosis performances verify that the optimum feature subset obtained by the presented method can dramatically improve power transformers fault diagnosis accuracy.

Compound Fault Diagnosis for Rotating Machinery:State-of-the-Art,Challenges,and Opportunities

Compound fault,as a primary failure leading to unexpected downtime of rotating machinery,dramatically increases the difficulty in fault diagnosis.To deal with the difficulty encountered in implementing compound fault diagnosis(CFD),researchers and engineers from industry and academia have made numerous significant breakthroughs in recent years.Admittedly,many systematic surveys focused on fault diagnosis have been conducted by reputable researchers.Nevertheless,previous review articles paid more attention to fault diagnosis with several single or independent faults,resulting in that there is still lacking a comprehensive survey on CFD.Therefore,to fulfill the above requirements,it is necessary to provide an in-depth overview of fault diagnosis methods or algorithms for compound faults of rotating machinery and uncover potential challenges or opportunities that would guide and inspire readers to devote their efforts to promoting fault diagnosis technology more effective and practical.Specifically,the backgrounds,including the related definitions and a new taxonomy of CFD methods,are detailed according to the way of implementing compound fault recognition.Then,the stateof-the-art applications of CFD are overviewed based on relevant publications in the past decades.Finally,the challenges and opportunities associated with implementing CFD are concluded and followed by a conclusion for ending this survey.We believe that this review article can provide a systematic guideline of CFD from different aspects for potential readers and seasoned researchers.

RMA-CNN:A Residual Mixed Domain Attention CNN for Bearings Fault Diagnosis and Its Time-Frequency Domain Interpretability

Early fault diagnosis of bearings is crucial for ensuring safe and reliable operations.Convolutional neural networks(CNNs)have achieved significant breakthroughs in machinery fault diagnosis.However,complex and varying working conditions can lead to inter-class similarity and intra-class variability in datasets,making it more challenging for CNNs to learn discriminative features.Furthermore,CNNs are often considered“black boxes”and lack sufficient interpretability in the fault diagnosis field.To address these issues,this paper introduces a residual mixed domain attention CNN method,referred to as RMA-CNN.This method comprises multiple residual mixed domain attention modules(RMAMs),each employing one attention mechanism to emphasize meaningful features in both time and channel domains.This significantly enhances the network’s ability to learn fault-related features.Moreover,we conduct an in-depth analysis of the inherent feature learning mechanism of the attention module RMAM to improve the interpretability of CNNs in fault diagnosis applications.Experiments conducted on two datasets—a high-speed aeronautical bearing dataset and a motor bearing dataset—demonstrate that the RMA-CNN achieves remarkable results in diagnostic tasks.