Research on Machine Tool Fault Diagnosis and Maintenance Optimization in Intelligent Manufacturing Environments

In the context of intelligent manufacturing,machine tools,as core equipment,directly influence production efficiency and product quality through their operational reliability.Traditional maintenance methods for machine tools,often characterized by low efficiency and high costs,fail to meet the demands of modern manufacturing industries.Therefore,leveraging intelligent manufacturing technologies,this paper proposes a solution optimized for the diagnosis and maintenance of machine tool faults.Initially,the paper introduces sensor-based data acquisition technologies combined with big data analytics and machine learning algorithms to achieve intelligent fault diagnosis of machine tools.Subsequently,it discusses predictive maintenance strategies by establishing an optimized model for maintenance strategy and resource allocation,thereby enhancing maintenance efficiency and reducing costs.Lastly,the paper explores the architectural design,integration,and testing evaluation methods of intelligent manufacturing systems.The study indicates that optimization of machine tool fault diagnosis and maintenance in an intelligent manufacturing environment not only enhances equipment reliability but also significantly reduces maintenance costs,offering broad application prospects.

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.

Dynamics and Fault Diagnosis of Railway Vehicle Gearboxes:A Review

The railway vehicle gearbox is an important part of the railway vehicle traction transmission system which ensures the smooth running of railway vehicles.However,as the running speed of railway vehicles continues to increase,the railway vehicle gearbox is exposed to a more demanding operating environment.Under both internal and external excitations,the gearbox is prone to faults such as fatigue cracks,and broken teeth.It is crucial to detect these faults before they result in severe failures and accidents.Therefore,understanding the dynamics and fault diagnosis of railway vehicle gearbox is needed.At present,there is a lack of systematic review of railway vehicle gearbox dynamics and fault diagnosis.So,this paper systematically summarizes the research progress on railway vehicle gearbox dynamics and fault diagnosis.To this end,this paper first summarizes the latest research progress on the dynamics of railway vehicle gearboxes.The dynamics and vibration characteristics of the gearbox are summarized under internal and external excitations,as well as faulty conditions.Then,the stateof-the-art signal processing and artificial intelligence methods for fault diagnosis of railway vehicle gearboxes are reviewed.In the end,future research prospects are given.

Signal-Based Intelligent Hydraulic Fault Diagnosis Methods: Review and Prospects

Hydraulic systems have the characteristics of strong fault concealment,powerful nonlinear time-varying signals,and a complex vibration transmission mechanism;hence,diagnosis of these systems is a challenge.To provide accurate diagnosis results automatically,numerous studies have been carried out.Among them,signal-based methods are commonly used,which employ signal processing techniques based on the state signal used for extracting features,and further input the features into the classifier for fault recognition.However,their main deficiencies include the following:(1)The features are manually designed and thus may have a lack of objectivity.(2)For signal processing,feature extraction and pattern recognition are conducted using independent models,which cannot be jointly optimized globally.(3)The machine learning algorithms adopted by these methods have a shallow architecture,which limits their capacity to deeply mine the essential features of a fault.As a breakthrough in artificial intelligence,deep learning holds the potential to overcome such deficiencies.Based on deep learning,deep neural networks(DNNs)can automatically learn the complex nonlinear relations implied in a signal,can be globally optimized,and can obtain the high-level features of multi-dimensional data.In this paper,the main technology used in an intelligent fault diagnosis and the current research status of hydraulic system fault diagnosis are summarized and analyzed.The significant prospect of applying deep learning in the field of intelligent fault diagnosis is presented,and the main ideas,methods,and principles of several typical DNNs are described and summarized.The commonality between a fault diagnosis and other issues regarding typical pattern recognition are analyzed,and research ideas for applying DNNs for hydraulic fault diagnosis are proposed.Meanwhile,the research advantages and development trend of DNNs(both domestically and overseas)as applied to an intelligent fault diagnosis are reviewed.Furthermore,the fault characteristics of a complex hydraulic system are summarized and discussed,and the key problems and possible research ideas of applying DNNs to an intelligent hydraulic fault diagnosis are presented and comprehensively analyzed.

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.

Comprehensive Overview on Computational Intelligence Techniques for Machinery Condition Monitoring and Fault Diagnosis

Computational intelligence is one of the most powerful data processing tools to solve complex nonlinear problems, and thus plays a significant role in intelligent fault diagnosis and prediction. However, only few com- prehensive reviews have summarized the ongoing efforts of computational intelligence in machinery condition moni- toring and fault diagnosis. The recent research and devel- opment of computational intelligence techniques in fault diagnosis, prediction and optimal sensor placement are reviewed. The advantages and limitations of computational intelligence techniques in practical applications are dis- cussed. The characteristics of different algorithms are compared, and application situations of these methods are summarized. Computational intelligence methods need to be further studied in deep understanding algorithm mech- anism, improving algorithm efficiency and enhancing engineering application. This review may be considered as a useful guidance for researchers in selecting a suit- able method for a specific situation and pointing out potential research directions.

Intelligent Fault Diagnosis of Rotary Machinery Based on Unsupervised Multiscale Representation Learning

The performance of traditional vibration based fault diagnosis methods greatly depends on those hand- crafted features extracted using signal processing algo- rithms, which require significant amounts of domain knowledge and human labor, and do not generalize well to new diagnosis domains. Recently, unsupervised represen- tation learning provides an alternative promising solution to feature extraction in traditional fault diagnosis due to its superior learning ability from unlabeled data. Given that vibration signals usually contain multiple temporal struc- tures, this paper proposes a multiscale representation learning （MSRL） framework to learn useful features directly from raw vibration signals, with the aim to capture rich and complementary fault pattern information at dif- ferent scales. In our proposed approach, a coarse-grained procedure is first employed to obtain multiple scale signals from an original vibration signal. Then, sparse filtering, a newly developed unsupervised learning algorithm, is applied to automatically learn useful features from each scale signal, respectively, and then the learned features at each scale to be concatenated one by one to obtain multi- scale representations. Finally, the multiscale representa- tions are fed into a supervised classifier to achieve diagnosis results. Our proposed approach is evaluated using two different case studies： motor bearing and wind turbine gearbox fault diagnosis. Experimental results show that the proposed MSRL approach can take full advantages of the availability of unlabeled data to learn discriminative features and achieved better performance with higher accuracy and stability compared to the traditional approaches.

Deep Learning Based Intelligent Industrial Fault Diagnosis Model

In the present industrial revolution era,the industrial mechanical system becomes incessantly highly intelligent and composite.So,it is necessary to develop data-driven and monitoring approaches for achieving quick,trustable,and high-quality analysis in an automated way.Fault diagnosis is an essential process to verify the safety and reliability operations of rotating machinery.The advent of deep learning(DL)methods employed to diagnose faults in rotating machinery by extracting a set of feature vectors from the vibration signals.This paper presents an Intelligent Industrial Fault Diagnosis using Sailfish Optimized Inception with Residual Network(IIFD-SOIR)Model.The proposed model operates on three major processes namely signal representation,feature extraction,and classification.The proposed model uses a Continuous Wavelet Transform(CWT)is for preprocessed representation of the original vibration signal.In addition,Inception with ResNet v2 based feature extraction model is applied to generate high-level features.Besides,the parameter tuning of Inception with the ResNet v2 model is carried out using a sailfish optimizer.Finally,a multilayer perceptron(MLP)is applied as a classification technique to diagnose the faults proficiently.Extensive experimentation takes place to ensure the outcome of the presented model on the gearbox dataset and a motor bearing dataset.The experimental outcome indicated that the IIFD-SOIR model has reached a higher average accuracy of 99.6%and 99.64%on the applied gearbox dataset and bearing dataset.The simulation outcome ensured that the proposed model has attained maximum performance over the compared methods.

A novel sparse filtering approach based on time-frequency feature extraction and softmax regression for intelligent fault diagnosis under different speeds

Modern agricultural mechanization has put forward higher requirements for the intelligent defect diagnosis.However,the fault features are usually learned and classified under all speeds without considering the effects of speed fluctuation.To overcome this deficiency,a novel intelligent defect detection framework based on time-frequency transformation is presented in this work.In the framework,the samples under one speed are employed for training sparse filtering model,and the remaining samples under different speeds are adopted for testing the effectiveness.Our proposed approach contains two stages:1)the time-frequency domain signals are acquired from the mechanical raw vibration data by the short time Fourier transform algorithm,and then the defect features are extracted from time-frequency domain signals by sparse filtering algorithm;2)different defect types are classified by the softmax regression using the defect features.The proposed approach can be employed to mine available fault characteristics adaptively and is an effective intelligent method for fault detection of agricultural equipment.The fault detection performances confirm that our approach not only owns strong ability for fault classification under different speeds,but also obtains higher identification accuracy than the other methods.

Digital Twin-Based Automated Fault Diagnosis in Industrial IoT Applications

In recent years, Digital Twin (DT) has gained significant interestfrom academia and industry due to the advanced in information technology,communication systems, Artificial Intelligence (AI), Cloud Computing (CC),and Industrial Internet of Things (IIoT). The main concept of the DT isto provide a comprehensive tangible, and operational explanation of anyelement, asset, or system. However, it is an extremely dynamic taxonomydeveloping in complexity during the life cycle that produces a massive amountof engendered data and information. Likewise, with the development of AI,digital twins can be redefined and could be a crucial approach to aid theInternet of Things (IoT)-based DT applications for transferring the data andvalue onto the Internet with better decision-making. Therefore, this paperintroduces an efficient DT-based fault diagnosis model based on machinelearning (ML) tools. In this framework, the DT model of the machine isconstructed by creating the simulation model. In the proposed framework,the Genetic algorithm (GA) is used for the optimization task to improvethe classification accuracy. Furthermore, we evaluate the proposed faultdiagnosis framework using performance metrics such as precision, accuracy,F-measure, and recall. The proposed framework is comprehensively examinedusing the triplex pump fault diagnosis. The experimental results demonstratedthat the hybrid GA-ML method gives outstanding results compared to MLmethods like LogisticRegression (LR), Na飗e Bayes (NB), and SupportVectorMachine (SVM). The suggested framework achieves the highest accuracyof 95% for the employed hybrid GA-SVM. The proposed framework willeffectively help industrial operators make an appropriate decision concerningthe fault analysis for IIoT applications in the context of Industry 4.0.

Comparative Study on Tool Fault Diagnosis Methods Using Vibration Signals and Cutting Force Signals by Machine Learning Technique

The state of cutting tool determines the quality of surface produced on the machined parts.A faulty tool produces poor sur face,inaccurate geometry and non-economic production.Thus,it is necessary to monitor tool condition for a.machining process to have superior quality and economic production.In the pre-sent study,fault classification of single point cutting tool for hard turning has been carried out by employing machine learning technique.Cutting force and vibration signals were acquired to monitor tool condition during machining.A set of four tooling conditions namely healthy,worn flank,broken insert and extended tool overhang have been considered for the study.The machine learning technique was applied to both vibration and cutting force signals.Discrete wavelet features of the signals have been extracted using discrete wavelet trans formation(DWT).This transformation represents a large dataset into approximation coeffcients which contain the most useful information of the dataset.Significant features,among features extracted,were selected using J48 decision tree technique.Clas-sification of tool conditions was carried out us ing Naive Bayes algorithm.A 10 fold cross validation was incorporated to test the validity of classifier.A comparison of performance of classifier was made between cutting force and vibration signal to choose the best signal acquisition method in classifying tool fault conditions using machine learning technique.

Detection and Diagnosis of Gear Fault By the Single Gear Tooth Analysis Technique

This paper presents a procedure of sing le gear tooth analysis for early detection and diagnosis of gear faults. The objec tive of this procedure is to develop a method for more sensitive detection of th e incipient faults and locating the faults in the gear. The main idea of the sin gle gear tooth analysis is that the vibration signals collected with a high samp ling rate are divided into a number of segments with the same time interval. The number of signal segments is equal to that of the gear teeth. The analysis of i ndividual segments reveals more sensitively the changes of the vibration signals in both time and frequency domain caused by gear faults. In addition, the locat ion of a failed tooth can be indicated in terms of the position of the segment t hat deviates from the normal segments. An experimental investigation verified th e advantages of the single gear tooth analysis.

Fault Diagnosis of an Intelligent Building Facility Using Bayesian Networks

There is great significance to diagnose the fault of an intelligent building facility for fault controlling, repairing, eliminating and preventing. As an example, this paper established a Bayesian networks model f or fault diagnosis of the refrigeration system of an intelligent building facility, gave the networks parameters, and analyzed the reasoning mechanism. Based on the model, some data was analyzed and diagnosed by adopting Bayesian networks reasoning platform GeNIe. The result shows that the diagnosis effect is more comprehensive and reasonable than the other method.

Bearings Intelligent Fault Diagnosis by 1-D Adder Neural Networks

Integrated with sensors,processors,and radio frequency(RF)communication modules,intelligent bearing could achieve the autonomous perception and autonomous decision-making,guarantying the safety and reliability during their use.However,because of the resource limitations of the end device,processors in the intelligent bearing are unable to carry the computational load of deep learning models like convolutional neural network(CNN),which involves a great amount of multiplicative operations.To minimize the computation cost of the conventional CNN,based on the idea of AdderNet,a 1-D adder neural network with a wide first-layer kernel(WAddNN)suitable for bearing fault diagnosis is proposed in this paper.The proposed method uses the l1-norm distance between filters and input features as the output response,thus making the whole network almost free of multiplicative operations.The whole model takes the original signal as the input,uses a wide kernel in the first adder layer to extract features and suppress the high frequency noise,and then uses two layers of small kernels for nonlinear mapping.Through experimental comparison with CNN models of the same structure,WAddNN is able to achieve a similar accuracy as CNN models with significantly reduced computational cost.The proposed model provides a new fault diagnosis method for intelligent bearings with limited resources.

The Research on Hybrid Intelligent Fault-diagnosisSystem of CNC Machine Tools

After analyzing the structure and characteristics of the hybrid intelligent diagnosis system of CNC machine toolsCNC-HIDS), we describe the intelligent hybrid mechanism of the CNC-HIDS, and present the evaluation and the running instance of the system. Through tryout and validation, we attain satisfactory results.

Intelligent fault diagnosis methods toward gas turbine: A review

Fault diagnosis plays a significant role in conducting condition-based maintenance and health management for gas turbines(GTs) to improve reliability and reduce costs. Various diagnosis methods developed by modeling engine systems or certain components implement faults detection and diagnosis based on the measurement of systemic parameters deviations. However, these conventional model-based methods are hindered by limitations of inability to handle the nonlinear nature, measurement uncertainty, fault coupling and other implementing problems. Recently, the development of artificial intelligence algorithms has provided an effective solution to the above problems, triggering broad researches for data-driven fault diagnosis methods with better accuracy,dynamic performance, and universality. This paper presents a systematic review of recently proposed intelligent fault diagnosis methods for GT engines, according to the classification of shallow learning methods, deep learning methods and hybrid intelligent methods. Moreover, the principle of typical algorithms, the evolution of enhanced methods, and the assessment of pros and cons are summarized to conclude the present status and look forward to the future in the field of GT fault diagnosis. Possible directions for development in method validation, information fusion, and interpretability of intelligent diagnosis methods are concluded in the end to provide insightful concepts for scholars in related fields.

Intelligent Diagnosis of Short Hydraulic Signal Based on Improved EEMD and SVM with Few Low-dimensional Training Samples

The high accurate classification ability of an intelligent diagnosis method often needs a large amount of training samples with high-dimensional eigenvectors, however the characteristics of the signal need to be extracted accurately. Although the existing EMD（empirical mode decomposition） and EEMD（ensemble empirical mode decomposition） are suitable for processing non-stationary and non-linear signals, but when a short signal, such as a hydraulic impact signal, is concerned, their decomposition accuracy become very poor. An improve EEMD is proposed specifically for short hydraulic impact signals. The improvements of this new EEMD are mainly reflected in four aspects, including self-adaptive de-noising based on EEMD, signal extension based on SVM（support vector machine）, extreme center fitting based on cubic spline interpolation, and pseudo component exclusion based on cross-correlation analysis. After the energy eigenvector is extracted from the result of the improved EEMD, the fault pattern recognition based on SVM with small amount of low-dimensional training samples is studied. At last, the diagnosis ability of improved EEMD＋SVM method is compared with the EEMD＋SVM and EMD＋SVM methods, and its diagnosis accuracy is distinctly higher than the other two methods no matter the dimension of the eigenvectors are low or high. The improved EEMD is very propitious for the decomposition of short signal, such as hydraulic impact signal, and its combination with SVM has high ability for the diagnosis of hydraulic impact faults.

Mechanical Fault Diagnosis Using Support Vector Machine

The Support Vector Machine (SVM) is a machine learning algorithm based on theStatistical Learning Theory (SLT), which can get good classification effects even with a fewlearning samples. SVM represents a new approach to pattern classification and has been shown to beparticularly successful in many fields such as image identification and face recognition. It alsoprovides us with a new method to develop intelligent fault diagnosis. This paper presents aSVM-based approach for fault diagnosis of rolling bearings. Experimentation with vibration signalsof bearings is conducted. The vibration signals acquired from the bearings are used directly in thecalculating without the preprocessing of extracting its features. Compared with the methods basedon Artificial Neural Network (ANN), the SVM-based method has desirable advantages. It is applicablefor on-line diagnosis of mechanical systems.

Machinery fault diagnosis expert system based on case-based reasoning

A mechinery fault diagnosis expert system based on case-based reasoning (CBR) technology was established. The process of the CBR fault diagnosis is analyzed from three main aspects: expression and memory, retrieving and matching, and modification and maintenance of a case. The results indicate that the CBR method is flexible and simple to implement, and it has strong self-studying ability. Using a large enough number of case reasoning sets, it can accumulate the experience of problem solving, avoid the difficulty of knowledge acquisition, shorten the course of solving problems, improve efficiency of reasoning, and save the time of developing.