1. Introduction
As a pivotal component in modern power infrastructure, SF
6 high-voltage circuit breakers have become the industry standard for high-current interruption in transmission systems operating at 110 kV and above [
1]. These gas-insulated switching devices leverage SF
6’s unique dielectric and arc-quenching properties to provide reliable circuit protection against both overload and short-circuit conditions [
2]. Their widespread adoption stems from three fundamental advantages: (1) exceptional dielectric strength (approximately three times that of air at atmospheric pressure), (2) superior thermal conductivity for arc energy dissipation, and (3) chemical stability under normal operating conditions.
The operational architecture of SF6 HVCBs integrates four critical subsystems that collectively ensure interruption reliability: (i) the arc-extinguishing unit, featuring precision-engineered main/arcing contacts and nozzle geometries optimized for gas flow dynamics; (ii) a composite insulation system utilizing epoxy resin insulators and gas-insulated switchgear (GIS) enclosures; (iii) high-speed operating mechanisms (hydraulic/pneumatic/spring) capable of achieving contact separation within milliseconds; and (iv) real-time gas monitoring systems tracking density and moisture content as key performance indicators.
The interruption process exemplifies a sophisticated multi-physics phenomenon, progressing through three distinct yet interdependent stages. Initial contact separation generates an arc column reaching ~20,000 K, causing SF
6 molecular dissociation into conductive S/F plasma. The puffer mechanism then drives supersonic gas flows (300–500 m/s) that simultaneously cool the arc channel through a convective heat transfer and turbulently disrupt plasma continuity. Crucially, SF
6’s electronegativity facilitates rapid dielectric recovery via electron attachment reactions (SF
6 + e
− → SF
6−), achieving critical insulation strength within 1–2 μs post current-zero—a key factor preventing thermal resignation. This coordinated thermochemical-hydrodynamic process enables interruption ratings exceeding 63 kA while maintaining arcing durations below 15 ms, representing a ~40% performance improvement over conventional air-blast breakers [
3].
However, in actual operation, the performance of SF
6 high-voltage circuit breakers is influenced by both internal and external factors, leading to potential failure risks. On the one hand, internal factors such as gas leakage, reduced gas purity, aging, or wear of mechanical components over prolonged use degrade the performance of SF
6 high-voltage circuit breakers [
4,
5]. On the other hand, external environmental changes interact with internal risk factors, exacerbating failures. Particularly under the increasing trend of extreme global climate conditions, this negative cycle becomes more pronounced, with extreme weather conditions even directly triggering failures. Evaluating and predicting the operational state of SF
6 high-voltage circuit breakers, and taking maintenance actions in advance before failures occur, can mitigate their impact on power system operations, which is of great significance for the safe operation of those systems.
At present, many researchers have proposed numerous evaluation methods for the operational status of high-voltage circuit breakers, which can be categorized into five types based on technical principles and application characteristics. The first category is statistical model-based reliability analysis. For instance, Xiang Zhang et al. derived the failure probability, failure rate, and remaining service life of equipment and components by statistically investigating records of unfiled components and maintenance measures [
6]. The second category relies on analyzing physical parameters to assess the operational status, where mechanical characteristics (e.g., closing and opening time, speed) [
7] or electrical signals (e.g., arc, current characteristics) [
8,
9] are monitored to detect whether the circuit breaker operates normally. The third category is the fusion of signal analysis and intelligent algorithms, such as fault detection through vibration signal spectrum analysis [
10], acoustic signal analysis [
11], and contact monitoring using a breaker contact state recognition model based on vibration signals and improved neural networks [
12]. Kuan Zhang et al. established a high-voltage circuit breaker fault diagnosis model based on LVQ neural networks and vibration signal analysis, improving accuracy through a combination of PCA-SSA-LVQ algorithms [
13]. Xinyu Ye et al. optimized diagnostic accuracy and adaptability for small-sample data using a one-dimensional attention-based convolutional capsule neural network [
14]. Yao et al. combined fractal technology and probabilistic neural networks (PNNs) to classify faults [
15]. The fourth category involves data-driven and hybrid models that build empirical models using big data mining and machine learning. Yang et al. integrated fuzzy mathematics, expert systems, and machine learning techniques to establish predictive models [
16]. Geng et al. optimized feature indicators and operational conditions to improve BP neural network performance [
17]. Žarković et al. [
18] employed artificial intelligence approaches incorporating cluster analysis (k-means, clustering tree) and artificial neural networks (ANNs) for health state assessment of SF
6 circuit breakers. The fifth category of methods comprises knowledge-based approaches that rely on domain expertise and prior knowledge to construct models or decision systems. Diahovchenko et al. [
19] applied fuzzy logic to evaluate the health status of SF
6 circuit breakers and optimize maintenance priorities. Reference [
20] integrated predictive data of dynamic contact resistance under varying current levels with domain expert knowledge to establish an expert system for assessing the contact erosion state, thereby providing explicit guidance for operation and maintenance decisions. Reference [
21] utilized association rules to calculate fault risks of individual components within high-voltage circuit breaker subsystems, proposing both subsystem maintenance strategies considering fault correlations and multi-component combined maintenance strategies, which offer theoretical references for formulating maintenance strategies for high-voltage circuit breakers.
While the aforementioned methods have achieved certain progress in fault diagnosis of high-voltage circuit breakers as documented in the literature, they still exhibit significant limitations. Primarily, most existing studies demonstrate excessive reliance on single-dimensional data, lacking effective integration of multi-source heterogeneous data. Firstly, current research methodologies predominantly exhibit limitations in their one-dimensional data dependency and insufficient integration of multisource heterogeneous data. Conventional approaches, such as vibration signal analysis or traditional parameter monitoring, typically focus on singular parameter dimensions during modeling and prediction, thereby failing to account for the inherent complexity of actual power equipment. In contrast, Reference [
22] proposes a more comprehensive fault prediction framework based on robust auto-associative kernel regression (AAKR), which systematically incorporates multiple critical parameters and still ignores the coupling effects of external environmental factors (e.g., temperature, humidity, mechanical vibration interference) on fault characteristics, leading to insufficient robustness of diagnostic models in complex working conditions. Although statistical models and data-driven methods utilize historical data, they do not explicitly model the dynamic relationship between environmental parameters and equipment aging, making them less adaptable to variable field conditions. Existing intelligent algorithms primarily optimize single-signal types without considering the synergistic analysis of mechanical and environmental parameters, leading to incomplete feature representation. Hybrid models and data-driven methods attempt to combine multiple techniques but fail to establish a cross-domain feature fusion mechanism, making it difficult to quantify the sensitivity of faults to environmental disturbances. Furthermore, association rule mining (ARM) approaches face inherent methodological limitations. First, the inherent variability in data quantity and the ambiguous definition of items frequently necessitate the lowering of mining threshold criteria to uncover quantitative association rules, resulting in the potential omission of significant patterns [
23]. More critically, conventional ARM implementations typically employ static computational methodologies regardless of the application context, failing to account for spatiotemporal variations in operational conditions, and the critical influence of high-risk characteristic factors during low-probability seasonal periods on SF
6 high-voltage circuit breaker performance.
To address these shortcomings in SF6 high-voltage circuit breaker operational status prediction, this study proposes a fault prediction method based on the Integrated Attribute-Weighted Risk Model Based on the Branch–Trunk Rule (IAR-BTR). This method comprehensively considers the impact of internal parameters and environmental factors on an SF6 high-voltage circuit breaker operation and can extract potential patterns of operational status from large-scale imbalanced data, thereby assessing whether failures will occur in the future. First, missing values in fault records are processed to filter reliable data. To facilitate feature management, different-dimensional feature matrices are standardized. Then, four types of association indicators are improved to encompass extreme factors and scenarios that are strongly correlated with SF6 high-voltage circuit breaker faults. In addition, BTR-based risk weight quantification is introduced to establish a relative risk weight calculation method that considers the interaction characteristics of various elements in SF6 high-voltage circuit breakers. This enables a more realistic and effective measurement of their varying impacts on overall system stability. The DFP-Growth algorithm is used for simulation. The effectiveness and flexibility of the proposed IAR-BTR model are verified through case studies, demonstrating its feasibility and adaptability for practical applications.
4. Empirical Case Study
4.1. Test Data
In this study, experimental validation was conducted using SF6 high-voltage circuit breaker records collected from power plants in a province of China. After missing value processing, a total of 521 sample records were obtained. The dataset was divided into training and testing subsets with a ratio of 7:3, where 70% of the records were used for training and 30% were reserved for testing.
4.2. Experimental Environment
The experimental environment consisted of two computing platforms: a high-performance with an Intel Core i7-7700 quad-core processor (3.6 GHz, 8 threads), 32 GB RAM, and 2 TB storage running 64-bit Windows, alongside a portable laptop configuration featuring an Intel Core i5-2450 M dual-core processor (2.5 GHz, 4 threads), 8 GB RAM, and 500 GB storage under the same 64-bit Windows OS. All computational procedures were executed in MATLAB R2022a (Math Works) as the unified software environment, ensuring consistent experimental conditions across both hardware platforms while maintaining the necessary computational capacity for algorithm benchmarking.
4.3. Validation Method
To validate the superiority of the proposed IAR-BTR method, this study selected several widely used classification models, including LGBM [
29], Tabular Neural Network [
30,
31], and Naive Bayes (NB) [
32], to establish fault prediction models for SF
6 high-voltage circuit breakers and compare their performance with that of the IAR-BTR method. A 10-fold cross-validation strategy was employed to ensure the reliability and robustness of the evaluation results. Through repeated testing, the optimal values of the key hyper parameters for each model are presented in
Table 3.
The performance of the models was comprehensively assessed using four metrics: Receiver Operating Characteristic (ROC) curve [
33], Precision-Recall (PR) curve [
34], Kolmogorov–Smirnov (KS) curve [
35], Detection Error Tradeoff (DET) curve [
36], Confusion Matrix [
37], Accuracy and Precision.
The evaluation metrics are described as follows:
The ROC curve reflects the overall classification performance of a model across different decision thresholds. Based on the ROC curve, the Area Under the Curve (AUC) is calculated as a quantitative metric; a higher AUC value indicates better overall classification accuracy.
- 2.
PR Curve:
The PR curve measures the relationship between precision and recall under varying thresholds and is particularly suitable for scenarios with imbalanced class distributions. Similarly to the ROC curve, the area under the PR curve can also serve as a reference for model performance evaluation.
- 3.
KS Curve and Optimal Threshold Selection:
While the ROC curve provides an overall assessment of model performance, the optimal classification threshold is determined using the KS curve. The Kolmogorov–Smirnov (KS) test, proposed by A.N. Kolmogorov and N.V. Smirnov, is based on cumulative distribution functions (CDFs) and is used to compare a sample with a reference probability distribution or to compare two samples.
- 4.
DET Curve:
The Detection Error Tradeoff (DET) curve quantitatively characterizes the tradeoff between the False Negative Rate (FNR) and the False Positive Rate (FPR), providing a rigorous framework for evaluating binary classifiers. The DET curve plots FPR on the x-axis and FNR on the y-axis, where a lower FNR corresponds to a better detection performance. Unlike the ROC curve, the lower the DET curve is, the better is the predictive performance of the system.
- 5.
Confusion Matrix:
The confusion matrix serves as a fundamental evaluation metric for classification models, providing a tabular representation of predicted versus actual class labels. This matrix structure comprises four critical components: true positives (TPs, correctly predicted positive instances), false positives (FPs, negative instances incorrectly classified as positive), false negatives (FNs, positive instances erroneously rejected), and true negatives (TNs, correctly identified negative cases). Particularly valuable for fault diagnosis in power equipment—where misclassification costs are substantial—the confusion matrix enables explicit quantification of model performance through specificity (TN/(FP + TN)) and sensitivity (TP/(TP + FN)) metrics, offering critical insights into a classifier’s discriminative capability across different fault types.
- 6.
Accuracy and Precision:
Accuracy measures the overall proportion of correct predictions made by the model, calculated as:
Precision quantifies the proportion of true positive instances among all samples predicted as positive, computed as:
4.4. Test Result Analysis
The ROC and PR curves were plotted for each method in
Figure 3, and the AUC values of each model were calculated and listed in
Table 4 and
Table 5.
From the above simulation, it is evident that the IAR-BTR model proposed in this paper can achieve the highest fault diagnosis accuracy, with the AUC values of ROC and PR being 0.9137 and 0.8923, respectively. In contrast, the accuracy of other classifier models is lower, and the AUC values under the PR curve are roughly the same. It can also be inferred from the side that, when dealing with high-dimensional data and imbalanced data distribution, this method can achieve satisfactory results compared to existing ordinary machine learning methods.
Figure 4 presents the KS curves of the IAR-BTR, LGBM, Tabular Neural Network and NB models in predicting the operational status of SF
6 high-voltage circuit breakers on the test set, visually illustrating each model’s ability to distinguish between fault and non-fault states. KS values of each model were listed in
Table 6. The KS curve of the IAR-BTR model exhibits the highest peak among the four, with a KS value of 0.8115—the highest among all methods—indicating that the incorporation of spatiotemporal non-stationary risk factors, through improved filtering thresholds and metric score calculations, significantly enhances the model’s discriminative capability.
Figure 5 presents the DET curves of the IAR-BTR, LGBM, Tabular Neural Network and NB models in predicting the operational status of SF
6 high-voltage circuit breakers on the test set. Analysis of the DET curve reveals that the IAR-BTR model’s curve is generally closest to the lower-left corner, indicating its superior ability to simultaneously reduce both the False Negative Rate (FNR) and the False Positive Rate (FPR). In this study, the IAR-BTR model achieves a significantly lower FNR and FPR compared to traditional approaches. This advantage stems from its environment-aware architecture, which effectively addresses the limitation of existing models that overlook external environmental factors. Future work will focus on quantifying the economic impact of reduced false alarms on power grid operation and maintenance.
Figure 6 Confusion matrices of the four models: (a) IAR-BTR, (b) LGBM, (c) Tabular Neural Network, (d) NB presents the confusion matrices of the four models, providing a visual representation of their classification performance. Based on the results, we quantitatively evaluated the model performance by calculating the accuracy and precision metrics for all four models, with detailed numerical results presented in
Table 7.
Comparative analysis demonstrates the superior performance of our proposed method across all evaluation metrics. The proposed method achieved exceptional accuracy (95.78%) and precision (97.22%), correctly identifying 499 out of 521 data samples, with only 22 misclassified instances. The confusion matrix analysis further confirms the robustness and significant performance advantages of our proposed method over the three baseline models.
5. Limitations of the Model and Possible Future Directions
This study has certain limitations that should be acknowledged. First, due to experimental constraints, the proposed model was primarily compared with classical machine learning approaches, while more recent advanced algorithms were not included in the benchmarking analysis. Second, the model validation was conducted using circuit breaker operational data from a single substation, which may not fully represent the performance variations across different voltage levels (e.g., 750 kV and above) or diverse operating conditions. These limitations highlight the need for more comprehensive comparisons and broader validation in future research.
Future research directions will focus on three key enhancements to advance the state-of-the-art in circuit breaker condition monitoring: First, we will incorporate cutting-edge algorithms (e.g., transformer-based architectures and graph neural networks) to optimize multi-parameter fusion strategies through attention mechanisms and cross-modal feature learning. Second, in collaboration with national grid operators, we will establish a comprehensive validation framework using multi-voltage-level operational data (spanning 110 kV to 800 kV) to rigorously evaluate model generalizability across diverse infrastructure configurations. Third, we will develop an environmental adaptive module that dynamically integrates real-time correction factors for temperature, humidity, and other atmospheric variables, while further investigating the impacts of extreme natural disasters (including seismic events and flood conditions) on high-voltage circuit breaker degradation patterns through physics-informed machine learning approaches.