A Deep Neural Network (DNN) based algorithm is proposed for the detection and classification of faults in industrial plants. The proposed algorithm has the ability to classify faults, especially incipient faults that are difficult to detect and diagnose with traditional threshold based statistical methods or by conventional Artificial Neural Networks (ANNs). The algorithm is based on a Supervised Deep Recurrent Autoencoder Neural Network (Supervised DRAE-NN) that uses dynamic information of the process along the time horizon. Based on this network a hierarchical structure is formulated by grouping faults based on their similarity into subsets of faults for detection and diagnosis. Further, an external pseudo-random binary signal (PRBS) is designed and injected into the system to identify incipient faults. The hierarchical structure based strategy improves the detection and classification accuracy significantly for both incipient and non-incipient faults. The proposed approach is tested on the benchmark Tennessee Eastman Process resulting in significant improvements in classification as compared to both multivariate linear model-based strategies and non-hierarchical nonlinear model-based strategies.
Advancing machine fault diagnosis: A detailed examination of convolutional neural networks
Wroclaw University of Science and Technology（弗罗茨瓦夫理工大学）；University of Ottawa（渥太华大学）；Sant Longowal Institute of Engineering and Technology（桑特隆戈瓦尔工程技术学院）
Nanyang Technological University（南洋理工大学）；University of California, Davis（加州大学戴维斯分校）
Machine learning-based methods have achieved successful applications in machinery fault diagnosis. However, the main limitation that exists for these methods is that they operate as a black box and are generally not interpretable. This paper proposes a novel neural network structure, called temporal logic neural network (TLNN), in which the neurons of the network are logic propositions. More importantly, the network can be described and interpreted as a weighted signal temporal logic. TLNN not only keeps the nice properties of traditional neuron networks but also provides a formal interpretati…
University of Electronic Science and Technology of China（电子科技大学）
Intelligent diagnosis method based on data-driven and deep learning is an attractive and meaningful field in recent years. However, in practical application scenarios, the imbalance of time-series fault is an urgent problem to be solved. This paper proposes a novel deep metric learning model, where imbalanced fault data and a quadruplet data pair design manner are considered. Based on such data pair, a quadruplet loss function which takes into account the inter-class distance and the intra-class data distribution are proposed. This quadruplet loss pays special attention to imbalanced sample pa…
Class Incremental Fault Diagnosis under Limited Fault Data via Supervised Contrastive Knowledge Distillation
ZJU-UIUC Joint Institute at Zhejiang University（浙江大学-伊利诺伊大学厄巴纳-香槟分校联合研究所）；ZJU-UoE Institute at Zhejiang University（浙江大学-爱丁堡大学联合研究所）；College of Biomedical Engineering and Instrument Science at Zhejiang University（浙江大学生物医学工程与仪器科学学院）；College of Computer Science and Technology in Zhejiang University（浙江大学计算机科学与技术学院）
Generalized Out-of-distribution Fault Diagnosis (GOOFD) via Internal Contrastive Learning
Zhejiang University and the University of Illinois Urbana–Champaign Joint Institute（浙江大学与伊利诺伊大学厄巴纳-香槟分校联合研究院）；College of Computer Science and Technology in Zhejiang University（浙江大学计算机科学与技术学院）
Shanghai University（上海大学）；University of Hawai‘i at Mānoa（夏威夷大学马诺阿分校）
Bearing fault identification and analysis is an important research area in the field of machinery fault diagnosis. Aiming at the common faults of rolling bearings, we propose a data-driven diagnostic algorithm based on the characteristics of bearing vibrations called multi-size kernel based adaptive convolutional neural network (MSKACNN). Using raw bearing vibration signals as the inputs, MSKACNN provides vibration feature learning and signal classification capabilities to identify and analyze bearing faults. Ball mixing is a ball bearing production quality problem that is difficult to identif…
Graph Neural Network-Based Semi-Supervised Open-Set Fault Diagnosis for Marine Machinery Systems
Intelligent Transportation School, Zhejiang Institute of Communications, China（浙江交通学院智能交通学院）；Center for Applied Intelligent Systems Research, Halmstad University, Sweden（哈马碧大学应用智能系统研究中心）
National University of Singapore（新加坡国立大学）；Temasek Laboratories（淡马锡实验室）
Accurate diagnosis of propeller faults is crucial for ensuring the safe and efficient operation of quadrotors. Training a fault classifier using simulated data and deploying it on a real quadrotor is a cost-effective and safe approach. However, the simulation-to-reality gap often leads to poor performance of the classifier when applied in real flight. In this work, we propose a deep learning model that addresses this issue by utilizing newly identified features (NIF) as input and utilizing domain adaptation techniques to reduce the simulation-to-reality gap. In addition, we introduce an adjust…
University of Electronic Science and Technology of China（电子科技大学）；Shenzhen Institute for Advanced Study（深圳高等研究院）
Considering the models that apply the contextual information of time-series data could improve the fault diagnosis performance, some neural network structures such as RNN, LSTM, and GRU were proposed to model the fault diagnosis effectively. However, these models are restricted by their serial computation and hence cannot achieve high diagnostic efficiency. Also the parallel CNN is difficult to implement fault diagnosis in an efficient way because it requires larger convolution kernels or deep structure to achieve long-term feature extraction capabilities. Besides, BERT model applies absolute …
Intelligent fault diagnosis is essential to safe operation of machinery. However, due to scarce fault samples and data heterogeneity in field machinery, deep learning based diagnosis methods are prone to over-fitting with poor generalization ability. To solve the problem, this paper proposes a personalized federated learning framework, enabling multi-task fault diagnosis method across multiple factories in a privacypreserving manner. Firstly, rotating machines from different factories with similar vibration feature data are categorized into machine groups using a federated clustering method. T…
School of Mechanical Engineering, Federal University of Uberlândia（Uberlândia联邦大学机械工程学院）；University of Padova（帕多瓦大学）；Federal University of São João del Rei（圣若昂德尔雷伊联邦大学）
The monitoring of rotating machinery is an essential task in today's production processes. Currently, several machine learning and deep learning-based modules have achieved excellent results in fault detection and diagnosis. Nevertheless, to further increase user adoption and diffusion of such technologies, users and human experts must be provided with explanations and insights by the modules. Another issue is related, in most cases, with the unavailability of labeled historical data that makes the use of supervised models unfeasible. Therefore, a new approach for fault detection and diagnosis…
CReSTIC（兰斯大学计算机科学与数字技术研究中心）；UFR Exact and Natural Sciences（精确与自然科学学院）
The problem considered in this paper is the online diagnosis of Automated Production Systems with sensors and actuators delivering discrete binary signals that can be modeled as Discrete Event Systems. Even though there are numerous diagnosis methods, none of them can meet all the criteria of implementing an efficient diagnosis system (such as an intelligent solution, an average effort, a reasonable cost, an online diagnosis, fewer false alarms, etc.). In addition, these techniques require either a correct, robust, and representative model of the system or relevant data or experts' knowledge t…
Cloud Ensemble Learning for Fault Diagnosis of Rolling Bearings with Stochastic Configuration Networks
Artificial Intelligence Research Institute, China University of Mining and Technology（中国矿业大学人工智能研究院）；School of Information and Control Engineering, China University of Mining and Technology（中国矿业大学信息与控制工程学院）；National Engineering Research Center of Coal Preparation and Purification, China University of Mining and Technology（中国矿业大学选煤国家工程研究中心）
Recent artificial intelligence-based methods have shown great promise in the use of neural networks for real-time sensing and detection of transmission line faults and estimation of their locations. The expansion of power systems including transmission lines with various lengths have made a fault detection, classification, and location estimation process more challenging. Transmission line datasets are stream data which are continuously collected by various sensors and hence, require generalized and fast fault diagnosis approaches. Newly collected datasets including voltages and currents might…
The emergence of large scaled sensor networks facilitates the collection of large amounts of real-time data to monitor and control complex engineering systems. However, in many cases the collected data may be incomplete or inconsistent, while the underlying environment may be time-varying or un-formulated. In this paper, we have developed an innovative cognitive fault diagnosis framework that tackles the above challenges. This framework investigates fault diagnosis in the model space instead of in the signal space. Learning in the model space is implemented by fitting a series of models using …
Northeast Electric Power University（东北电力大学）；Technical University of Denmark（丹麦技术大学）
Three-phase PWM rectifiers are adopted extensively in industry because of their excellent properties and potential advantages. However, while the IGBT has an open-circuit fault, the system does not crash suddenly, the performance will be reduced for instance voltages fluctuation and current harmonics. A fault diagnosis method based on deep feedforward network with transient synthetic features is proposed to reduce the dependence on the fault mathematical models in this paper, which mainly uses the transient phase current to train the deep feedforward network classifier. Firstly, the features o…
The fault diagnosis of rolling bearings is a critical technique to realize predictive maintenance for mechanical condition monitoring. In real industrial systems, the main challenges for the fault diagnosis of rolling bearings pertain to the accuracy and real-time requirements. Most existing methods focus on ensuring the accuracy, and the real-time requirement is often neglected. In this paper, considering both requirements, we propose a novel fast fault diagnosis method for rolling bearings, based on extreme learning machine (ELM) and logistic mapping, named logistic-ELM. First, we identify 1…
In this study, the open-circuit faults diagnosis and location issue of the neutral-point-clamped (NPC) inverters are analysed. A novel fault diagnosis approach based on knowledge driven and data driven was presented for the open-circuit faults in insulated-gate bipolar transistors (IGBTs) of NPC inverter, and Concordia transform (knowledge driven) and random forests (RFs) technique (data driven) are employed to improve the robustness performance of the fault diagnosis classifier. First, the fault feature data of AC in either normal state or open-circuit faults states of NPC inverter are analys…
Zhejiang University（浙江大学）；University of Illinois Urbana–Champaign（伊利诺伊大学厄巴纳-香槟分校）；University of Science and Technology Beijing（北京科技大学）
Intelligent fault diagnosis has made extraordinary advancements currently. Nonetheless, few works tackle class-incremental learning for fault diagnosis under limited fault data, i.e., imbalanced and long-tailed fault diagnosis, which brings about various notable challenges. Initially, it is difficult to extract discriminative features from limited fault data. Moreover, a well-trained model must be retrained from scratch to classify the samples from new classes, thus causing a high computational burden and time consumption. Furthermore, the model may suffer from catastrophic forgetting when tra…
The scope of data-driven fault diagnosis models is greatly extended through deep learning (DL). However, the classical convolution and recurrent structure have their defects in computational efficiency and feature representation, while the latest Transformer architecture based on attention mechanism has not yet been applied in this field. To solve these problems, we propose a novel time-frequency Transformer (TFT) model inspired by the massive success of vanilla Transformer in sequence processing. Specially, we design a fresh tokenizer and encoder module to extract effective abstractions from …
Center for Risk and Reliability, University of Maryland, College Park（马里兰大学帕克分校风险与可靠性中心）；Department of Civil and Environmental Engineering, University of California, Los Angeles（加利福尼亚大学洛杉矶分校土木与环境工程系）；Garrick Institute for the Risk Sciences, University of California, Los Angeles（加利福尼亚大学洛杉矶分校加里克风险科学研究所）；Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University（香港理工大学工业与系统工程系）；Centre for Advances in Reliability and Safety Limited (CAiRS)（可靠性及安全进展中心有限公司）
There has been a growing interest in deep learning-based prognostic and health management (PHM) for building end-to-end maintenance decision support systems, especially due to the rapid development of autonomous systems. However, the low trustworthiness of PHM hinders its applications in safety-critical assets when handling data from an unknown distribution that differs from the training dataset, referred to as the out-of-distribution (OOD) dataset. To bridge this gap, we propose an uncertainty-informed framework to diagnose faults and meanwhile detect the OOD dataset, enabling the capability …
University of Michigan（密歇根大学）；University of Texas Medical Branch（德克萨斯大学医学部）；Institute for Translational Sciences（转化科学研究所）；Electrical Engineering and Computer Science（电气工程与计算机科学学院）
The problem of active diagnosis arises in several applications such as disease diagnosis, and fault diagnosis in computer networks, where the goal is to rapidly identify the binary states of a set of objects (e.g., faulty or working) by sequentially selecting, and observing, (noisy) responses to binary valued queries. Current algorithms in this area rely on loopy belief propagation for active query selection. These algorithms have an exponential time complexity, making them slow and even intractable in large networks. We propose a rank-based greedy algorithm that sequentially chooses queries s…
Fault diagnosis of dynamic systems is done by detecting changes in time-series data, for example residuals, caused by system degradation and faulty components. The use of general-purpose multi-class classification methods for fault diagnosis is complicated by imbalanced training data and unknown fault classes. Another complicating factor is that different fault classes can result in similar residual outputs, especially for small faults, which causes classification ambiguities. In this work, a framework for data-driven analysis and open-set classification is developed for fault diagnosis applic…
Northeast Electric Power University（东北电力大学）；Technical University of Denmark（丹麦技术大学）
A fault diagnosis method for power electronics converters based on deep feedforward network and wavelet compression is proposed in this paper. The transient historical data after wavelet compression are used to realize the training of fault diagnosis classifier. Firstly, the correlation analysis of the voltage or current data running in various fault states is performed to remove the redundant features and the sampling point. Secondly, the wavelet transform is used to remove the redundant data of the features, and then the training sample data is greatly compressed. The deep feedforward networ…
SCCAM: Supervised Contrastive Convolutional Attention Mechanism for Ante-hoc Interpretable Fault Diagnosis with Limited Fault Samples
Zhejiang University（浙江大学）；University of Illinois Urbana–Champaign Institute（伊利诺伊大学厄巴纳-香槟分校学院）；Southeast University（东南大学）；Huazhong University of Science and Technology（华中科技大学）
A growing number of wind turbines are equipped with vibration measurement systems to enable a close monitoring and early detection of developing fault conditions. The vibration measurements are analyzed to continuously assess the component health and prevent failures that can result in downtimes. This study focuses on gearbox monitoring but is applicable also to other subsystems. The current state-of-the-art gearbox fault diagnosis algorithms rely on statistical or machine learning methods based on fault signatures that have been defined by human analysts. This has multiple disadvantages. Defi…
Recent trends focusing on Industry 4.0 concept and smart manufacturing arise a data-driven fault diagnosis as key topic in condition-based maintenance. Fault diagnosis is considered as an essential task in rotary machinery since possibility of an early detection and diagnosis of the faulty condition can save both time and money. Traditional data-driven techniques of fault diagnosis require signal processing for feature extraction, as they are unable to work with raw signal data, consequently leading to need for expert knowledge and human work. The emergence of deep learning architectures in co…
Inspired by recent progress in machine learning, a data-driven fault diagnosis and isolation (FDI) scheme is explicitly developed for failure in the fuel supply system and sensor measurements of the laboratory gas turbine system. A passive approach of fault diagnosis is implemented where a model is trained using machine learning classifiers to detect a given set of fault scenarios in real-time on which it is trained. Towards the end, a comparative study is presented for well-known classification techniques, namely Support vector classifier, linear discriminant analysis, K-neighbor, and decisio…
Bangladesh University of Engineering and Technology（孟加拉国工程技术大学）
An intrinsic time-scale decomposition (ITD) based method for power transformer fault diagnosis is proposed. Dissolved gas analysis (DGA) parameters are ranked according to their skewness, and then ITD based features extraction is performed. An optimal set of PRC features are determined by an XGBoost classifier. For classification purpose, an XGBoost classifier is used to the optimal PRC features set. The proposed method's performance in classification is studied using publicly available DGA data of 376 power transformers and employing an XGBoost classifier. The Proposed method achieves more th…
Due to the different losses caused by various photovoltaic (PV) array faults, accurate diagnosis of fault types is becoming increasingly important. Compared with a single one, multiple PV stations collect sufficient fault samples, but their data is not allowed to be shared directly due to potential conflicts of interest. Therefore, federated learning can be exploited to train a collaborative fault diagnosis model. However, the modeling efficiency is seriously affected by the model update mechanism since each PV station has a different computing capability and amount of data. Moreover, for the …
ADVA Optical Networking SE（ADVA光网络公司）；Christian-Albrechts-Universität zu Kiel（基尔大学）
We propose a deep learning approach based on an autoencoder for identifying and localizing fiber faults in passive optical networks. The experimental results show that the proposed method detects faults with 97% accuracy, pinpoints them with an RMSE of 0.18 m and outperforms conventional techniques.
Quantum computing (QC) and deep learning techniques have attracted widespread attention in the recent years. This paper proposes QC-based deep learning methods for fault diagnosis that exploit their unique capabilities to overcome the computational challenges faced by conventional data-driven approaches performed on classical computers. Deep belief networks are integrated into the proposed fault diagnosis model and are used to extract features at different levels for normal and faulty process operations. The QC-based fault diagnosis model uses a quantum computing assisted generative training p…
University of California, Berkeley（加州大学伯克利分校）；University of Chicago（芝加哥大学）
Intermediate-Severity (IS) faults present milder symptoms compared to severe faults, and are more difficult to detect and diagnose due to their close resemblance to normal operating conditions. The lack of IS fault examples in the training data can pose severe risks to Fault Detection and Diagnosis (FDD) methods that are built upon Machine Learning (ML) techniques, because these faults can be easily mistaken as normal operating conditions. Ensemble models are widely applied in ML and are considered promising methods for detecting out-of-distribution (OOD) data. We identify common pitfalls in t…
Thanks to digitization of industrial assets in fleets, the ambitious goal of transferring fault diagnosis models fromone machine to the other has raised great interest. Solving these domain adaptive transfer learning tasks has the potential to save large efforts on manually labeling data and modifying models for new machines in the same fleet. Although data-driven methods have shown great potential in fault diagnosis applications, their ability to generalize on new machines and new working conditions are limited because of their tendency to overfit to the training set in reality. One promising…
German Research Center for Artificial Intelligence（德国人工智能研究中心）
Noncritical soft-faults and model deviations are a challenge for Fault Detection and Diagnosis (FDD) of resident Autonomous Underwater Vehicles (AUVs). Such systems may have a faster performance degradation due to the permanent exposure to the marine environment, and constant monitoring of component conditions is required to ensure their reliability. This works presents an evaluation of Recurrent Neural Networks (RNNs) for a data-driven fault detection and diagnosis scheme for underwater thrusters with empirical data. The nominal behavior of the thruster was modeled using the measured control …
