The Detection of Rolling-Element Bearing Faults in Non-stationary Quasi-Parallel Machinery Using Residual Analysis Augmented by Neural Networks
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Published
Sep 20, 2021
Dustin Helm
Markus Timusk
Abstract
This work proposes a methodology for the detection of rolling-element bearing faults in quasi-parallel machinery. In the context of this work, parallel machinery is considered to be any group of identical components of a mechanical system that are linked to operate on the same duty cycle. Quasi-parallel machinery can further be defined as two components not identical mechanically, but their operating conditions are correlated and they operate in the same environmental conditions. Furthermore, a new fault detection architecture is proposed wherein a feed-forward neural network (FFNN) is utilized to identify the relationship between signals. The proposed technique is based on the analysis of a calculated residual between feature vectors from two separate components. This technique is designed to reduce the effects of changes in the machines operating state on the condition monitoring system. When a fault detection system is monitoring multiple components in a larger system that are mechanically linked, signals and information that can be gleaned from the system can be used to reduce influences from factors that are not related to condition. The FFNN is used to identify the relationship between the feature vectors from two quasi-parallel components and eliminate the difference when no fault is present. The proposed method is tested on vibration data from two gearboxes that are connected in series. The gearboxes contain bearings operating at different speeds and gear mesh frequencies. In these conditions, a variety of rolling-element bearing faults are detected. The results indicate that improvement in fault detection accuracy can be achieved by using the additional information available from the quasi-parallel machine. The proposed method is directly compared to a typical AANN novelty detection scheme.
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Keywords
Condition Monitoring, Hardware Redundancy, Non-Stationary Operating Conditions, Auto-Associative Neural Network
References
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Gor, M. M., Pathak, P. M., Samantaray, A. K., Yang, J.-M., & Kwak, S. W. (2018). Fault accommodation in compliant quadruped robot through a moving appendage mechanism. Mechanism and Machine Theory, 121, 228–244. https://doi.org/10.1016/j.mechmachtheory.2017.10.011
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Helm, D., & Timusk, M. (2019). Fault detection for parallel operating machines. Journal of Quality in Maintenance Engineering, 26(2), 335–348.
Isermann, R., & Ballé, P. (1997). Trends in the application of model-based fault detection and diagnosis of technical processes. Control Engineering Practice, 5(5), 709–719. https://doi.org/10.1016/S0967-0661(97)00053-1
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Kramer, M.A. (1992). Autoassociative neural networks. Computers and Chemical Engineering, 16(4), 313–328. https://doi.org/10.1016/0098-1354(92)80051-A
Kramer, Mark A. (1991). Nonlinear principal component analysis using autoassociative neural networks. AIChE Journal, 37(2), 233–243. Retrieved from https://www.engineeringvillage.com/share/document.url?mid=cpx_1ef9f1d11c0a0637c629f62061377551&database=cpx
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Liu, R., Yang, B., Zio, E., & Chen, X. (2018). Artificial intelligence for fault diagnosis of rotating machinery: A review. Mechanical Systems and Signal Processing, 108, 33–47. https://doi.org/10.1016/j.ymssp.2018.02.016
McBain, J., Lakanen, G., & Timusk, M. (2013). Vibration- and acoustic-emissions based novelty detection of fretted bearings. Journal of Quality in Maintenance Engineering, 19(2), 181–198.
Principi, E., Rossetti, D., Squartini, S., & Piazza, F. (2019). Unsupervised electric motor fault detection by using deep autoencoders. IEEE/CAA Journal of Automatica Sinica, 6(2), 441–451. https://doi.org/10.1109/JAS.2019.1911393
Randall, R. B., & Antoni, J. (2011). Rolling element bearing diagnostics-A tutorial. Mechanical Systems and Signal Processing, 25(2), 485–520. https://doi.org/10.1016/j.ymssp.2010.07.017
Rose, A. M., Helm, D. M., & Timusk, M. (2016). Fault detection of parallel hydraulic pumps in non-stationary operation. International Journal of COMADEM, 19(3), 55–59.
Samanta, B. (2004). Gear fault detection using artificial neural networks and support vector machines with genetic algorithms. Mechanical Systems and Signal Processing, 18(3), 625–644. https://doi.org/10.1016/S0888-3270(03)00020-7
Samanta, B., & Al-Balushi, K. R. (2003). Artificial neural network based fault diagnostics of rolling element bearings using time-domain features. Mechanical Systems and Signal Processing, 17(2), 317–328. https://doi.org/10.1006/mssp.2001.1462
Sanz, J., Perera, R., & Huerta, C. (2007). Fault diagnosis of rotating machinery based on auto-associative neural networks and wavelet transforms. Journal of Sound and Vibration, 302(4–5), 981–999. https://doi.org/10.1016/j.jsv.2007.01.006
Shao, H., Jiang, H., Zhao, H., & Wang, F. (2017). A novel deep autoencoder feature learning method for rotating machinery fault diagnosis. Mechanical Systems and Signal Processing, 95, 187–204. https://doi.org/10.1016/j.ymssp.2017.03.034
Staroswiecki, M., & Comtet-Varga, G. (2001). Analytical redundancy relations for fault detection and isolation in algebraic dynamic systems. Automatica, 37(5), 687–699. https://doi.org/10.1016/S0005-1098(01)00005-X
Strczkiewicz, M., & Barszcz, T. (2016). Application of artificial neural network for damage detection in planetary gearbox of wind turbine. Shock and Vibration, 2016. https://doi.org/10.1155/2016/4086324
Timusk, M., Lipsett, M., & Mechefske, C. K. (2008). Fault detection using transient machine signals. Mechanical Systems and Signal Processing, 22(7), 1724–1749. https://doi.org/10.1016/j.ymssp.2008.01.013
Wang, G., & Cui, Y. (2013). On line tool wear monitoring based on auto associative neural network. Journal of Intelligent Manufacturing, 24(6), 1085–1094. https://doi.org/10.1007/s10845-012-0636-7
Wang, X., & Makis, V. (2009). Autoregressive model-based gear shaft fault diagnosis using the Kolmogorov-Smirnov test. Journal of Sound and Vibration, 327(3–5), 413–423. https://doi.org/10.1016/j.jsv.2009.07.004
Willersrud, A., Blanke, M., & Imsland, L. (2015). Incident detection and isolation in drilling using analytical redundancy relations. Control Engineering Practice, 41, 1–12. https://doi.org/10.1016/j.conengprac.2015.03.010
Xie, Y., & Zhang, T. (2017). Fault Diagnosis for Rotating Machinery Based on Convolutional Neural Network and Empirical Mode Decomposition. Shock and Vibration, 2017, 1–12. https://doi.org/10.1155/2017/3084197
Zhao, R., Yan, R., Chen, Z., Mao, K., Wang, P., & Gao, R. X. (2019). Deep learning and its applications to machine health monitoring. Mechanical Systems and Signal Processing, 115, 213–237. https://doi.org/10.1016/j.ymssp.2018.05.050
Abboud, D., Baudin, S., Antoni, J., Remond, D., Eltabach, M., & Sauvage, O. (2016). The spectral analysis of cyclo-non-stationary signals. Mechanical Systems and Signal Processing, 75, 280–300. https://doi.org/10.1016/j.ymssp.2015.09.034
Barakat, M., Druaux, F., Lefebvre, D., Khalil, M., & Mustapha, O. (2011). Self adaptive growing neural network classifier for faults detection and diagnosis. Neurocomputing, 74(18), 3865–3876. https://doi.org/10.1016/j.neucom.2011.08.001
Bin, G. F., Gao, J. J., Li, X. J., & Dhillon, B. S. (2012). Early fault diagnosis of rotating machinery based on wavelet packets - Empirical mode decomposition feature extraction and neural network. Mechanical Systems and Signal Processing, 27(1), 696–711. https://doi.org/10.1016/j.ymssp.2011.08.002
Chen, Z., & Mechefske, C. K. (2001). Model order selection: A practical approach. Mechanical Systems and Signal Processing, 15(2), 265–273. https://doi.org/10.1006/mssp.2000.1289
Cong, F., Chen, J., & Dong, G. (2012). Spectral kurtosis based on AR model for fault diagnosis and condition monitoring of rolling bearing. Journal of Mechanical Science and Technology, 26(2), 301–306. https://doi.org/10.1007/s12206-011-1029-0
Figueiredo, E., Figueiras, J., Park, G., Farrar, C. R., & Worden, K. (2011). Influence of the autoregressive model order on damage detection. Computer-Aided Civil and Infrastructure Engineering, 26(3), 225–238. https://doi.org/10.1111/j.1467-8667.2010.00685.x
Gertler, J. (1997). Fault detection and isolation using parity relations. Control Engineering Practice, 5(5), 653–661. https://doi.org/10.1016/S0967-0661(97)00047-6
Gianluca, N., Fromaigeat, L., & Etienne, L. (2016). Machine Learning Strategy for Fault Classification Using Only Nominal Data. In European Conference Of The Prognostics And Health Management Society.
Gor, M. M., Pathak, P. M., Samantaray, A. K., Yang, J.-M., & Kwak, S. W. (2018). Fault accommodation in compliant quadruped robot through a moving appendage mechanism. Mechanism and Machine Theory, 121, 228–244. https://doi.org/10.1016/j.mechmachtheory.2017.10.011
Hagan, M. T., & Menhaj, M. B. (1994). Training feed-forward networks with the Marquardt algorithm. IEEE Transactions on Neural Networks, 5(6), 989–993.
Haidong, S., Hongkai, J., Xingqiu, L., & Shuaipeng, W. (2018). Intelligent fault diagnosis of rolling bearing using deep wavelet auto-encoder with extreme learning machine. Knowledge-Based Systems, 140, 1–14. https://doi.org/10.1016/j.knosys.2017.10.024
Hao, Y., & Wilamowski, B. M. (2011). Levenberg-marquardt training. In Industrial electronics handbook (5th ed., pp. 12-1-12–15).
Helm, D. M., Rose, A. M., & Timusk, M. (2016). Condition monitoring of rolling-element bearings in parallel operating belt drive systems. International Journal of COMADEM, 19(3), 61–64.
Helm, D., & Timusk, M. (2017). Using residual analysis for detection of faults in unsteadily operating rolling element bearings. In WCCM 2017 - 1st World Congress on Condition Monitoring 2017.
Helm, D., & Timusk, M. (2019). Fault detection for parallel operating machines. Journal of Quality in Maintenance Engineering, 26(2), 335–348.
Isermann, R., & Ballé, P. (1997). Trends in the application of model-based fault detection and diagnosis of technical processes. Control Engineering Practice, 5(5), 709–719. https://doi.org/10.1016/S0967-0661(97)00053-1
Japkowicz, N., Myers, C., & Gluck, M. (1995). A Novelty Detection Approach to Classification. In 14th International Joint Conference on Artificial Intelligence (pp. 518–523).
Jia, F., Lei, Y., Lin, J., Zhou, X., & Lu, N. (2016). Deep neural networks: A promising tool for fault characteristic mining and intelligent diagnosis of rotating machinery with massive data. Mechanical Systems and Signal Processing, 72–73, 303–315. https://doi.org/10.1016/j.ymssp.2015.10.025
Jiang, H., Wang, F., Shao, H., & Zhang, H. (2017). Rolling bearing fault identification using multilayer deep learning convolutional neural network. Journal of Vibroengineering, 19(1), 138–149. https://doi.org/10.21595/jve.2016.16939
Liu, R., Yang, B., Zio, E., & Chen, X. (2018). Artificial intelligence for fault diagnosis of rotating machinery: A review. Mechanical Systems and Signal Processing, 108, 33–47. https://doi.org/10.1016/j.ymssp.2018.02.016
Kramer, M.A. (1992). Autoassociative neural networks. Computers and Chemical Engineering, 16(4), 313–328. https://doi.org/10.1016/0098-1354(92)80051-A
Kramer, Mark A. (1991). Nonlinear principal component analysis using autoassociative neural networks. AIChE Journal, 37(2), 233–243. Retrieved from https://www.engineeringvillage.com/share/document.url?mid=cpx_1ef9f1d11c0a0637c629f62061377551&database=cpx
Lei, Y., Lin, J., He, Z., & Zuo, M. J. (2013). A review on empirical mode decomposition in fault diagnosis of rotating machinery. Mechanical Systems and Signal Processing, 35(1–2), 108–126. https://doi.org/10.1016/j.ymssp.2012.09.015
Liu, R., Yang, B., Zio, E., & Chen, X. (2018). Artificial intelligence for fault diagnosis of rotating machinery: A review. Mechanical Systems and Signal Processing, 108, 33–47. https://doi.org/10.1016/j.ymssp.2018.02.016
McBain, J., Lakanen, G., & Timusk, M. (2013). Vibration- and acoustic-emissions based novelty detection of fretted bearings. Journal of Quality in Maintenance Engineering, 19(2), 181–198.
Principi, E., Rossetti, D., Squartini, S., & Piazza, F. (2019). Unsupervised electric motor fault detection by using deep autoencoders. IEEE/CAA Journal of Automatica Sinica, 6(2), 441–451. https://doi.org/10.1109/JAS.2019.1911393
Randall, R. B., & Antoni, J. (2011). Rolling element bearing diagnostics-A tutorial. Mechanical Systems and Signal Processing, 25(2), 485–520. https://doi.org/10.1016/j.ymssp.2010.07.017
Rose, A. M., Helm, D. M., & Timusk, M. (2016). Fault detection of parallel hydraulic pumps in non-stationary operation. International Journal of COMADEM, 19(3), 55–59.
Samanta, B. (2004). Gear fault detection using artificial neural networks and support vector machines with genetic algorithms. Mechanical Systems and Signal Processing, 18(3), 625–644. https://doi.org/10.1016/S0888-3270(03)00020-7
Samanta, B., & Al-Balushi, K. R. (2003). Artificial neural network based fault diagnostics of rolling element bearings using time-domain features. Mechanical Systems and Signal Processing, 17(2), 317–328. https://doi.org/10.1006/mssp.2001.1462
Sanz, J., Perera, R., & Huerta, C. (2007). Fault diagnosis of rotating machinery based on auto-associative neural networks and wavelet transforms. Journal of Sound and Vibration, 302(4–5), 981–999. https://doi.org/10.1016/j.jsv.2007.01.006
Shao, H., Jiang, H., Zhao, H., & Wang, F. (2017). A novel deep autoencoder feature learning method for rotating machinery fault diagnosis. Mechanical Systems and Signal Processing, 95, 187–204. https://doi.org/10.1016/j.ymssp.2017.03.034
Staroswiecki, M., & Comtet-Varga, G. (2001). Analytical redundancy relations for fault detection and isolation in algebraic dynamic systems. Automatica, 37(5), 687–699. https://doi.org/10.1016/S0005-1098(01)00005-X
Strczkiewicz, M., & Barszcz, T. (2016). Application of artificial neural network for damage detection in planetary gearbox of wind turbine. Shock and Vibration, 2016. https://doi.org/10.1155/2016/4086324
Timusk, M., Lipsett, M., & Mechefske, C. K. (2008). Fault detection using transient machine signals. Mechanical Systems and Signal Processing, 22(7), 1724–1749. https://doi.org/10.1016/j.ymssp.2008.01.013
Wang, G., & Cui, Y. (2013). On line tool wear monitoring based on auto associative neural network. Journal of Intelligent Manufacturing, 24(6), 1085–1094. https://doi.org/10.1007/s10845-012-0636-7
Wang, X., & Makis, V. (2009). Autoregressive model-based gear shaft fault diagnosis using the Kolmogorov-Smirnov test. Journal of Sound and Vibration, 327(3–5), 413–423. https://doi.org/10.1016/j.jsv.2009.07.004
Willersrud, A., Blanke, M., & Imsland, L. (2015). Incident detection and isolation in drilling using analytical redundancy relations. Control Engineering Practice, 41, 1–12. https://doi.org/10.1016/j.conengprac.2015.03.010
Xie, Y., & Zhang, T. (2017). Fault Diagnosis for Rotating Machinery Based on Convolutional Neural Network and Empirical Mode Decomposition. Shock and Vibration, 2017, 1–12. https://doi.org/10.1155/2017/3084197
Zhao, R., Yan, R., Chen, Z., Mao, K., Wang, P., & Gao, R. X. (2019). Deep learning and its applications to machine health monitoring. Mechanical Systems and Signal Processing, 115, 213–237. https://doi.org/10.1016/j.ymssp.2018.05.050
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Technical Papers