Search

In the process of metal wire and additive manufacturing, due to changes in temperature, humidity, current, voltage, and other parameters, as well as the failure of machinery and equipment, a failure may occur in the manufacturing process that seriously affects the current situation of production efficiency and product quality. Based on the demand for monitoring of the key impact parameters of additive manufacturing, this paper develops a parameter monitoring and prediction system for the additive manufacturing feeding process to provide a basis for future fault diagnosis. The fault diagnosis and prediction system for metal wire supply and additive manufacturing utilizes STM 32 as its core, enabling the capture and transmission of temperature, humidity, current, and voltage data. The upper computer system, designed on the LabVIEW 2019 virtual instrument platform, incorporates an LSTM neural network model and facilitates a connection between LabVIEW and MATLAB 2019 to achieve the prediction function. The monitoring and prediction system established in this study is intended to provide basic research assistance in the field of fault diagnosis. [ABSTRACT FROM AUTHOR]

Currently, many fault diagnosis methods for rolling bearings based on deep learning are facing two main challenges. Firstly, the deep learning model exhibits poor diagnostic performance and limited generalization ability in the presence of noise signals and varying loads. Secondly, there is incomplete utilization of fault information and inadequate extraction of fault features, leading to the low diagnostic accuracy of the model. To address these problems, this paper proposes an improved dual-branch convolutional capsule neural network for rolling bearing fault diagnosis. This method converts the collected bearing vibration signals into grayscale images to construct a grayscale image dataset. By fully considering the types of bearing faults and damage diameters, the data are labeled using a dual-label format. A multi-scale convolution module is introduced to extract features from the data and maximize feature information extraction. Additionally, a coordinate attention mechanism is incorporated into this module to better extract useful channel features and enhance feature extraction capability. Based on adaptive fusion between fault type (damage diameter) features and labels, a dual-branch convolutional capsule neural network model for rolling bearing fault diagnosis is established. The model was experimentally validated using both Case Western Reserve University's bearing dataset and self-made datasets. The experimental results demonstrate that the fault type branch of the model achieves an accuracy rate of 99.88%, while the damage diameter branch attains an accuracy rate of 99.72%. Both branches exhibit excellent classification performance and display robustness against noise interference and variable working conditions. In comparison with other algorithm models cited in the reference literature, the diagnostic capability of the model proposed in this study surpasses them. Furthermore, the generalization ability of the model is validated using a self-constructed laboratory dataset, yielding an average accuracy rate of 94.25% for both branches. [ABSTRACT FROM AUTHOR]

Photovoltaic (PV) panels are one of the popular green energy resources and PV panel parameter estimations are one of the popular research topics in PV panel technology. The PV panel parameters could be used for PV panel health monitoring and fault diagnosis. Recently, a PV panel parameters estimation method based in neural network and numerical current predictor methods has been developed. However, in order to further improve the estimation accuracies, a new approach of PV panel parameter estimation is proposed in this paper. The output current and voltage dynamic responses of a PV panel are measured, and the time series of the I–V vectors will be used as input to an artificial neural network (ANN)-based PV model parameter range classifier (MPRC). The MPRC is trained using an I–V dataset with large variations in PV model parameters. The results of MPRC are used to preset the initial particles' population for a particle swarm optimization (PSO) algorithm. The PSO algorithm is used to estimate the PV panel parameters and the results could be used for PV panel health monitoring and the derivation of maximum power point tracking (MMPT). Simulations results based on an experimental I–V dataset and an I–V dataset generated by simulation show that the proposed algorithms can achieve up to 3.5% accuracy and the speed of convergence was significantly improved as compared to a purely PSO approach. [ABSTRACT FROM AUTHOR]

This paper proposes fault diagnosis methods aimed at proactively preventing potential safety issues in robot systems, particularly human coexistence robots (HCRs) used in industrial environments. The data were collected from durability tests of the driving module for HCRs, gathering time-series vibration data until the module failed. In this study, to apply classification methods in the absence of post-failure data, the initial 50% of the collected data were designated as the normal section, and the data from the 10 h immediately preceding the failure were selected as the fault section. To generate additional data for the limited fault dataset, the Wasserstein generative adversarial networks with gradient penalty (WGAN-GP) model was utilized and residual connections were added to the generator to maintain the basic structure while preventing the loss of key features of the data. Considering that the performance of image encoding techniques varies depending on the dataset type, this study applied and compared five image encoding methods and four CNN models to facilitate the selection of the most suitable algorithm. The time-series data were converted into image data using image encoding techniques including recurrence plot, Gramian angular field, Markov transition field, spectrogram, and scalogram. These images were then applied to CNN models, including VGGNet, GoogleNet, ResNet, and DenseNet, to calculate the accuracy of fault diagnosis and compare the performance of each model. The experimental results demonstrated significant improvements in diagnostic accuracy when employing the WGAN-GP model to generate fault data, and among the image encoding techniques and convolutional neural network models, spectrogram and DenseNet exhibited superior performance, respectively. [ABSTRACT FROM AUTHOR]

Because of its long running time, complex working environment, and for other reasons, a gear is prone to failure, and early failure is difficult to detect by direct observation; therefore, fault diagnosis of gears is very necessary. Neural network algorithms have been widely used to realize gear fault diagnosis, but the structure of the neural network model is complicated, the training time is long and the model is not easy to converge. To solve the above problems and combine the advantages of the ResNeXt50 model in the extraction of image features, this paper proposes a gearbox fault detection method that integrates the convolutional block attention module (CBAM). Firstly, the CBAM is embedded in the ResNeXt50 network to enhance the extraction of image channels and spatial features. Secondly, the different time–frequency analysis method was compared and analyzed, and the method with the better effect was selected to convert the one-dimensional vibration signal in the open data set of the gearbox into a two-dimensional image, eliminating the influence of the redundant background noise, and took it as the input of the model for training. Finally, the accuracy and the average training time of the model were obtained by entering the test set into the model, and the results were compared with four other classical convolutional neural network models. The results show that the proposed method performs well both in fault identification accuracy and average training time under two working conditions, and it also provides some references for existing gear failure diagnosis research. [ABSTRACT FROM AUTHOR]

With the development of industrial manufacturing intelligence, the role of rotating machinery in industrial production and life is more and more important. Aiming at the problems of the complex and changeable working environment of rolling bearings and limited computing ability, fault feature information cannot be effectively extracted, and the current deep learning model is difficult to be compatible with lightweight and high efficiency. Therefore, this paper proposes a fault detection method for power equipment based on an energy spectrum diagram and deep learning. Firstly, a novel two-dimensional time-frequency feature representation method and energy spectrum feature map based on wavelet packet transform is proposed, and an energy spectrum feature map dataset is made for subsequent diagnosis. This method can realize multi-resolution analysis, fully extract the feature information contained in the fault signal, and accelerate the convergence of the subsequent diagnosis model. Secondly, a lightweight residual dense convolutional neural network model (LR-DenseNet) is proposed. This model combines the advantages of residual learning and a dense connection, and can not only extract deep features more easily, but can also effectively use shallow features. Then, based on the lightweight residual dense convolutional neural network model, an LR-DenseSENet model is proposed. By introducing the transfer learning strategy and adding the channel domain, an attention mechanism is added to the channel feature fusion layer, with the accuracy of detection up to 99.4%, and the amount of parameter calculation greatly reduced to one-fifth of that of VGG. Finally, through an experimental analysis, it is verified that the fault detection model designed in this paper based on the combination of an energy spectrum feature map and LR-DenseSENet achieves a satisfactory detection effect. [ABSTRACT FROM AUTHOR]

Currently, the online non-destructive testing (NDT) methods to measure the contact states of high-voltage circuit breakers (HVCBs) with SF6 gas as a quenching medium are lacking. This paper aims to put forward a novel method to detect the contact state of an HVCB based on the vibrational signal. First, for a 40.5-kV SF6 HVCB prototype, a mechanical vibration detection system along with a high-current generator to provide the test current is designed. Given this, vibration test experiments are carried out, and the vibration signal data under various currents and corresponding contact states are obtained. Afterward, a feature extraction method based on the frequency is designed. The state of the HVCB contacts is then determined using optimized deep neural networks (DNNs) along with the method of adaptive moment estimation (Adam) on the obtained experimental data. Finally, the hyperparameters for the DNNs are tuned using the Bayesian optimization (BO) technique, and a global HVCB contact state recognition model at various currents is proposed. The obtained results clearly depict that the proposed recognition model can accurately identify five various contact states of HVCBs for the currents between 1000 A and 3500 A, and the recognition accuracy rate is above 96%. The designed experimental and theoretical analysis in our study will provide the references for future monitoring and diagnosis of faults in HVCBs. [ABSTRACT FROM AUTHOR]

Vehicle fault detection and diagnosis (VFDD) along with predictive maintenance (PdM) are indispensable for early diagnosis in order to prevent severe accidents due to mechanical malfunction in urban environments. This paper proposes an early voiceprint driving fault identification system using machine learning algorithms for classification. Previous studies have examined driving fault identification, but less attention has focused on using voiceprint features to locate corresponding faults. This research uses 43 different common vehicle mechanical malfunction condition voiceprint signals to construct the dataset. These datasets were filtered by linear predictive coefficient (LPC) and wavelet transform(WT). After the original voiceprint fault sounds were filtered and obtained the main fault characteristics, the deep neural network (DNN), convolutional neural network (CNN), and long short-term memory (LSTM) architectures are used for identification. The experimental results show that the accuracy of the CNN algorithm is the best for the LPC dataset. In addition, for the wavelet dataset, DNN has the best performance in terms of identification performance and training time. After cross-comparison of experimental results, the wavelet algorithm combined with DNN can improve the identification accuracy by up to 16.57% compared with other deep learning algorithms and reduce the model training time by up to 21.5% compared with other algorithms. Realizing the cross-comparison of recognition results through various machine learning methods, it is possible for the vehicle to proactively remind the driver of the real-time potential hazard of vehicle machinery failure. [ABSTRACT FROM AUTHOR]

The fiber optic gyroscope (FOG) is a high precision inertial navigation device, and it is necessary to ensure its reliability for effective use. However, the extracted fault features are easily distorted due to the interference of vibrations when the FOG is in operation. In order to minimize the influence of vibrations to the greatest extent, a fusion diagnosis method was proposed in this paper. It extracted features from fault data with Fast Fourier Transform (FFT) and wavelet packet decomposition (WPD), and built a strong diagnostic classifier with a sparse auto encoder (SAE) and a neural network (NN). Then, a fusion neural network model was established based on the diagnostic output probabilities of the two primary classifiers, which improved the diagnostic accuracy and the anti-vibration capability. Then, five fault types of the FOG under random vibration conditions were established. Fault data sets were collected and generated for experimental comparison with other methods. The results showed that the proposed fusion fault diagnosis method could perform effective and robust fault diagnosis for the FOG under vibration conditions with a high diagnostic accuracy. [ABSTRACT FROM AUTHOR]

Induction motors play a key role in the industrial sector. Thus, the correct diagnosis and classification of faults on these machines are important, even in the initial stages of evolution. Such analysis allows for increased productivity, avoids unexpected process interruptions, and prevents damage to machines. Usually, fault diagnosis is carried out by analyzing the characteristic effects caused by the faults. Thus, it is necessary to know and understand the behavior during the operation of the faulty machine. In general, monitoring these characteristics is complex, as it is necessary to acquire signals from the same motor with and without failures for comparison purposes. Whether in an industrial environment or in laboratories, the experimental characterization of failures can become unfeasible for several reasons. Thus, computer simulation of faulty motors digital twins can be an important alternative for failure analysis, especially in large motors. From this perspective, this paper presents and discusses several limitations found in the technical literature that can be minimized with the implementation of digital twins. In addition, a 3D finite element model of an induction motor with broken rotor bars is demonstrated, and motor current signature analysis is used to verify the fault effects. Results are analyzed in the time and frequency domain. Additionally, an artificial neural network of the multilayer perceptron type is used to classify the failure of broken bars in the 3D model rotor. [ABSTRACT FROM AUTHOR]

This paper proposes an approach to estimate the state of health of DC-DC converters that feed the electrical system of an electric vehicle. They have an important role in providing a smooth and rectified DC voltage to the electric machine. Thus, it is important to diagnose the actual status and predict the future performance of the converter and specifically of the electrolytic capacitors, in order to avoid malfunctioning and failures, since it is known they have the highest failure rates among power converter components. To this end, accelerated aging tests of the electrolytic capacitors are performed by applying an electrical overstress. The gathered data are used to train a CNN-LSTM model that is capable of predicting the future values of the capacitance and the equivalent series resistance (ESR) of the electrolytic capacitor. This model can be used to estimate the remaining useful life of the device, thus, increasing the reliability of the system and ensuring an adequate operating condition of the electric motor. [ABSTRACT FROM AUTHOR]

Bearings are critical components found in most rotating machinery; their health condition is of immense importance to many industries. The varied conditions and environments in which bearings operate make them prone to single and multiple faults. Widespread interest in the improvements of single fault diagnosis meant limited attention was spent on multiple fault diagnosis. However, multiple fault diagnosis poses extra challenges due to the submergence of the weak fault by the strong fault, presence of non-Gaussian noise, coupling of the frequency components, etc. A number of existing convolutional neural network models operate on a distinct feature that is not enough to assure reliable results in the presence of these challenges. In this paper, extended feature sets in three homogenous deep learning models are used for multiple fault diagnosis. This ensures a measure of diversity is introduced to the health management dataset to obtain complementary solutions from the models. The outputs of the models are fused through blending ensemble learning. Experiments using vibration datasets based on bearing multiple faults show an accuracy of 98.54%, with an improvement of 2.74% in the overall effectiveness over the single models. Compared with other technologies, the results show that this approach provides an improved generalized diagnostic capability. [ABSTRACT FROM AUTHOR]