scholarly journals Application of PCA and Classification for Fault Diagnosis of MAB Installed in Petrochemical Plant Process Facilities

2021 ◽  
Vol 11 (9) ◽  
pp. 3780
Author(s):  
Se-Yun Hwang ◽  
Kwang-Sik Kim ◽  
Hyung-Jin Kim ◽  
Hong-Bae Jun ◽  
Jang-Hyun Lee
Keyword(s):  
Fault Diagnosis ◽  
Operating Conditions ◽  
Suggested Method ◽  
Sensor Data ◽  
Actual Process ◽  
Petrochemical Plant ◽  
Pca Method ◽  
Diagnosis Model ◽  
Plant Process

In large systems, such as power plants or petrochemical plants, various equipment (e.g., compressors, pumps, turbines, etc.) are typically deployed. Each piece of equipment operates under generally harsh operating conditions, depending on its purpose, and operates with a probability of failure. Therefore, several sensors are attached to monitor the status of each piece of equipment to observe its conditions; however, there are many limitations in monitoring equipment using thresholds such as maximum and minimum values of data. Therefore, this study introduces a technology that can diagnose fault conditions by analyzing several sensor data obtained from plant operation information systems. The equipment for the case study was a main air blower (MAB), an important cooling equipment in the plant process. The driving sensor data were analyzed for approximately three years, measured at the plant. The fault history of the actual process was also analyzed. Due to the large number of sensors installed in the MAB system, a dimension reduction method was applied with the principal component analysis (PCA) method when analyzing collected sensor data. For application to PCA, the collected sensor data were analyzed according to the statistical analysis method and data features were extracted. Then, the features were labeled and classified according to normal and fault operating conditions. The analyzed features were converted with a diagnosis model, by dimensional reduction, applying the PCA method and a classification algorithm. Finally, to validate the diagnosis model, the actual failure signal that occurred in the plant was applied to the suggested method. As a result, the results from diagnosing signs of failure were confirmed even before the failure occurred. This paper explains the case study of fault diagnosis for MAB equipment with the suggested method and its results.

scholarly journals Blind Application of Developed Smart Vibration-Based Machine Learning (SVML) Model for Machine Faults Diagnosis to Different Machine Conditions

2020 ◽  
Author(s):  
Natalia F. Espinoza Sepúlveda ◽  
Jyoti K. Sinha
Keyword(s):  
Machine Learning ◽  
Fault Diagnosis ◽  
Condition Monitoring ◽  
Operating Conditions ◽  
Machine Vibration ◽  
Identical Machines ◽  
Vibration Responses ◽  
Faults Diagnosis ◽  
Diagnosis Model ◽  
Machine Speed

Abstract Purpose The development and application of intelligent models to perform vibration-based condition monitoring in industry seems to be receiving attention in recent years. A number of such research studies using the artificial intelligence, machine learning, pattern recognition, etc., are available in the literature on this topic. These studies essentially used the machine vibration responses with known machine faults to develop smart fault diagnosis models. These models are yet to be tested for all kinds of machine faults and/or different operating conditions. Therefore, the purpose is to develop a generic machine faults diagnosis model that can be applied blindly to any identical machines with high confidence level in accuracy of the predictions. Methods In this paper, a supervised smart fault diagnosis model is developed. This model is developed using the available measured vibration responses for the different rotor faults simulated on an experimental rotating rig operating at a constant speed. The developed smart vibration-based machine learning (SVML) model is then blindly tested to identify the healthy and faulty conditions of the rig when operating at different speeds. Results and conclusions Several scenarios are proposed and examined during the development of the SVML model. It is observed that scenario of the vibration measurements simultaneously from all bearings from a machine is capable to fully map the machine dynamics in the VML model. Therefore, this developed when applied blindly to the sets of data at a different machine speed, the results are observed to be encouraging. The results clearly show a possibility for a centralised vibration-based condition monitoring (CVCM) model for identical machines operating at different rotating speeds.

Early fault diagnosis of ball screws based on 1-D convolution neural network and orthogonal design

2021 ◽  
pp. 1748006X2199288
Author(s):  
Chen Yin ◽  
Yulin Wang ◽  
Yan He ◽  
Lu Liu ◽  
Yan Wang ◽  
...  
Keyword(s):  
Neural Network ◽  
Fault Diagnosis ◽  
State Of The Art ◽  
Orthogonal Design ◽  
Fault Classification ◽  
Optimal Parameters ◽  
One Dimensional ◽  
Learning Technique ◽  
Diagnosis Model

Ball screws, the most frequently used mechanical components to transform rotary motion into linear motion, can directly affect the precision and service life of engineering machines. Once the efficiency and accuracy of ball screws degrades, the performance and safety of machines are hard to guarantee. Conventional fault diagnosis researches of ball screws are mainly focused on ordinary faults such as preload loss and wear, and lack of the researches on early faults such as lubrication degradation which may progress into the ordinary faults. Additionally, the fault diagnosis models proposed in previous studies divide the fault diagnosis into two separated stages: feature extraction and fault classification, which prevents the usage for real-time applications. The specifically designed algorithm in features extraction stage may be also not workable on other objects. To tackle these drawbacks, this paper proposes a highly accurate early fault diagnosis model of ball screws based on a state-of-the-art deep learning technique, called One-Dimensional Convolutional Neural Network (1-D CNN). Experiments simulating the lubrication degradation of ball screws are specially designed for the early fault diagnosis of the ball screws. Moreover, a concise and efficient approach based on orthogonal design is exploited to scientifically obtain the optimal parameters of the 1-D CNN. The results of a case study verify the superiority of the proposed method in establishing a highly accurate 1-D CNN based fault diagnosis model.

Roller Element Bearing of Mine Ventilating Fan with Fault Diagnosis Based on Mechanics Properties and RBF Neural Network

2012 ◽  
Vol 625 ◽  
pp. 125-129
Author(s):  
Ying Hong Zhang ◽  
Cong Li ◽  
Hui Jing ◽  
Bing Bing Gao
Keyword(s):  
Neural Network ◽  
Fault Diagnosis ◽  
Radial Basis Function ◽  
Basis Function ◽  
Rbf Neural Network ◽  
Rbf Network ◽  
Bearing Fault Diagnosis ◽  
Element Bearing ◽  
Diagnosis Model

Roller element bearing is an important part of mine ventilating fan. The management and maintenance of the equipment is very important. Therefore, it is necessary to employ fault diagnosis process to the roller element bearing. In this paper, mechanics properties of roller element bearing are analyzed. Then, Radial Basis Function (RBF) neural network is used for the fault diagnosis of the roller element bearing. The structure and inference of RBF network are discussed in detail. The roller element bearing fault diagnosis model is established based on RBF network. A case study is given. The proposed method is applied to the fault diagnosis of roller element bearing. The result shows that the proposed method can improve efficiency of the fault diagnosis.

scholarly journals Deep Learning-based Approach for Fault Diagnosis of Rolling Element Bearings

2018 ◽  
Vol 10 (1) ◽  
Author(s):  
Mohammadkazem Sadoughi ◽  
Austin Downey ◽  
Garrett Bunge ◽  
Aditya Ranawat ◽  
Chao Hu ◽  
...  
Keyword(s):  
Fault Diagnosis ◽  
Fault Detection ◽  
Signal To Noise Ratio ◽  
Health Condition ◽  
Diagnostic Information ◽  
Sensor Data ◽  
Spectral Kurtosis ◽  
Shaft Misalignment ◽  
Processing Techniques

Condition monitoring and fault detection of roller element bearings is of vital importance to ensuring safe and reliable operation of rotating machinery systems. Over the past few years, convolutional neural network (CNN) has been recognized as a useful tool for fault detection of roller element bearings. Unlike the traditional fault diagnosis approaches, CNN does not require manually extracting the fault-related features from the raw sensor data and most CNN-based fault diagnosis approaches feed the raw or shallowly pre-processed data as the training/testing inputs to a CNN model, thereby avoiding the need for manual feature extraction. As such, these approaches can be considered as purely data-driven. However, it has been proven that some well-established signal pre-processing techniques such as spectral kurtosis and envelope analysis can effectively clean and pre-process a raw signal to be a better representative of the health condition of a bearing without losing critical diagnostic information. This study proposes a new approach to bearing fault diagnosis, termed the SK-based multi-channel CNN (SCNN), that combines signal pre-processing techniques with a modified 1D CNN. The proposed SCNN approach involves two main steps: in the first step, each raw sensor signal acquired from a bearing is pre-processed to maximize the signal-to-noise ratio without losing critical diagnostic information carried by the signal; and in the second step, all pre-processed signals are fed into a 1D multi-channel CNN that classifies the health condition of the bearing. An experimental case study was carried out to evaluate the performance of the proposed approach. In this case study, a machinery fault simulator was used to validate the performance of SCNN in the presence of faults unrelated to bearings such as shaft misalignment and rotor unbalance.

Study on Fault Diagnosis of Planetary Gearbox in Unmanned Aerial Vehicle Using Multi sensor Data

2020 ◽  
Vol 20 (4) ◽  
pp. 332-342
Author(s):  
Hyung Jun Park ◽  
Seong Hee Cho ◽  
Kyung-Hwan Jang ◽  
Jin-Woon Seol ◽  
Byung-Gi Kwon ◽  
...  
Keyword(s):  
Fault Diagnosis ◽  
Unmanned Aerial Vehicle ◽  
Sensor Data ◽  
Planetary Gearbox ◽  
Aerial Vehicle

Case Study on Fault Diagnosis of the Actual Operating Transformer by FRA

2011 ◽  
Vol 131 (1) ◽  
pp. 78-85 ◽  
Author(s):  
Takahiro Sano ◽  
Yoshiharu Ogawa ◽  
Takaaki Shimonosono ◽  
Tadayuki Wada
Keyword(s):  
Fault Diagnosis ◽  
Actual Operating

scholarly journals Fault Diagnosis of Brake Train Based on Multi-Sensor Data Fusion

Sensors ◽  
2021 ◽  
Vol 21 (13) ◽  
pp. 4370
Author(s):  
Yongze Jin ◽  
Guo Xie ◽  
Yankai Li ◽  
Xiaohui Zhang ◽  
Ning Han ◽  
...  
Keyword(s):  
Fault Diagnosis ◽  
Expectation Maximization ◽  
Monitoring Data ◽  
Sensor Data ◽  
Operating Environment ◽  
Mass Model ◽  
Multi Sensor Data Fusion ◽  
Diagnosis Method ◽  
Single Mass ◽  
Parameter Identifications

In this paper, a fault diagnosis method is proposed based on multi-sensor fusion information for a single fault and composite fault of train braking systems. Firstly, the single mass model of the train brake is established based on operating environment. Then, the pre-allocation and linear-weighted summation criterion are proposed to fuse the monitoring data. Finally, based on the improved expectation maximization, the braking modes and braking parameters are identified, and the braking faults are diagnosed in real time. The simulation results show that the braking parameters of systems can be effectively identified, and the braking faults can be diagnosed accurately based on the identification results. Even if the monitoring data are missing or abnormal, compared with the maximum fusion, the accuracies of parameter identifications and fault diagnoses can still meet the needs of the actual systems, and the effectiveness and robustness of the method can be verified.

scholarly journals Application of Deep Learning in Fault Diagnosis of Rotating Machinery

Processes ◽  
2021 ◽  
Vol 9 (6) ◽  
pp. 919
Author(s):  
Wanlu Jiang ◽  
Chenyang Wang ◽  
Jiayun Zou ◽  
Shuqing Zhang
Keyword(s):  
Neural Network ◽  
Feature Extraction ◽  
Fault Diagnosis ◽  
Rotating Machinery ◽  
Generative Adversarial Networks ◽  
Extraction Ability ◽  
One Dimensional ◽  
Adversarial Networks ◽  
Diagnosis Model ◽  
The One

The field of mechanical fault diagnosis has entered the era of “big data”. However, existing diagnostic algorithms, relying on artificial feature extraction and expert knowledge are of poor extraction ability and lack self-adaptability in the mass data. In the fault diagnosis of rotating machinery, due to the accidental occurrence of equipment faults, the proportion of fault samples is small, the samples are imbalanced, and available data are scarce, which leads to the low accuracy rate of the intelligent diagnosis model trained to identify the equipment state. To solve the above problems, an end-to-end diagnosis model is first proposed, which is an intelligent fault diagnosis method based on one-dimensional convolutional neural network (1D-CNN). That is to say, the original vibration signal is directly input into the model for identification. After that, through combining the convolutional neural network with the generative adversarial networks, a data expansion method based on the one-dimensional deep convolutional generative adversarial networks (1D-DCGAN) is constructed to generate small sample size fault samples and construct the balanced data set. Meanwhile, in order to solve the problem that the network is difficult to optimize, gradient penalty and Wasserstein distance are introduced. Through the test of bearing database and hydraulic pump, it shows that the one-dimensional convolution operation has strong feature extraction ability for vibration signals. The proposed method is very accurate for fault diagnosis of the two kinds of equipment, and high-quality expansion of the original data can be achieved.

scholarly journals Sparse Autoencoder-based Multi-head Deep Neural Networks for Machinery Fault Diagnostics with Detection of Novelties

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Zhe Yang ◽  
Dejan Gjorgjevikj ◽  
Jianyu Long ◽  
Yanyang Zi ◽  
Shaohui Zhang ◽  
...  
Keyword(s):  
Fault Diagnosis ◽  
Supervised Classification ◽  
Deep Neural Networks ◽  
Activation Function ◽  
Reconstruction Error ◽  
Fine Tuning ◽  
Fault Diagnostics ◽  
Sparse Autoencoder

AbstractSupervised fault diagnosis typically assumes that all the types of machinery failures are known. However, in practice unknown types of defect, i.e., novelties, may occur, whose detection is a challenging task. In this paper, a novel fault diagnostic method is developed for both diagnostics and detection of novelties. To this end, a sparse autoencoder-based multi-head Deep Neural Network (DNN) is presented to jointly learn a shared encoding representation for both unsupervised reconstruction and supervised classification of the monitoring data. The detection of novelties is based on the reconstruction error. Moreover, the computational burden is reduced by directly training the multi-head DNN with rectified linear unit activation function, instead of performing the pre-training and fine-tuning phases required for classical DNNs. The addressed method is applied to a benchmark bearing case study and to experimental data acquired from a delta 3D printer. The results show that its performance is satisfactory both in detection of novelties and fault diagnosis, outperforming other state-of-the-art methods. This research proposes a novel fault diagnostics method which can not only diagnose the known type of defect, but also detect unknown types of defects.

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