Gearbox Condition Monitoring and Diagnosis of Unlabeled Vibration Signals Using a Supervised Learning Classifier
Abstract
:1. Introduction
- Monitoring the behavior of a process (variables);
- Identifying faults, their characteristics, and their root causes.
- Steel-making plants continually switch between a load state (where they exert force for processing) and an idle state where they do not. Without a distinction between equipment operating conditions, it is difficult to detect changes in equipment status from the collected data. This difficulty can be overcome by eliminating noise in the data, recording the exact time of an occurrence (time stamping), and compiling event data.
- The data collected in the field on vibrations, temperatures, electric current, and debris inside the oil are often collected separately from the meta data (event data) that indicate the equipment’s operating condition. The equipment data collected cannot be labeled as failure or normal states, thus making it difficult to apply a supervised learning algorithm.
- When parts of the equipment are replaced, overhauled, or repaired, the characteristics of that equipment are altered. Because of this, the data on equipment status are not accurate, so they must be collected again to reflect the current normal status.
- Unlabeled vibration data can be pseudolabeled and used to monitor changes in equipment conditions using a supervised learning classifier.
- It is possible to reduce false alarms due to periodic changes in equipment operating under normal conditions.
- We confirm the timing of equipment condition changes.
- A quantitative analysis was performed, and relationships between independent and dependent variables are explained to determine which features affect equipment abnormalities.
2. Related Work
- When an artificial failure is created, labeled, and then analyzed, it is unlikely to produce the same results in the field.
- When a methodology cannot be applied directly at the production site because only vibration signals are collected without normal presence-and-absence labels.
- When fault alarms are inevitable if the equipment characteristics include repeated accelerations, decelerations, and stopping while operating, and they are subject to temporary influences from the surrounding environment.
- When normal states of the equipment constantly change, whether because of regular repairs, overhauls, oil replenishment, or minor repairs.
3. Equipment Condition Monitoring
3.1. The Proposed Reduced Lagrange Method
- The first arrow indicates that the input data set is entered into the classifier (C). On the right side of Figure 1a, you can see the unfolded tasks for each time sequence. describes the structure of the input data set and refers to normal and abnormal data sets, respectively. Data set in the ith time sequence is labeled normal up front. Data set in the jth time sequence is labeled abnormal later. In the data structure, you can see that the first data sets are all the same, , which indicates that you have a data set that can be considered normal. The data sets prepared for each time sequence are considered abnormal and are used as input for the classifier.
- The second arrow indicates that the evaluation metric is created and stored in the classifier. A pseudolabeled data set is input, and the classifier stores the classification performance. represents the classification evaluation performance of the classifier at time sequence .
- The topmost arrows execute the classifier repeatedly. and denote the classifier and the nth time sequence, respectively.
3.2. Procedure for Equipment Monitoring and Fault Detection
Algorithm 1 Procedure for equipment condition monitoring based on the R-LM |
Input: |
Input data set structure defined as . |
where is a data set pseudolabeled normal in the ith time sequence. |
is a data set pseudolabeled abnormal in the th time sequence. |
For each iteration k: |
is fixed during k iterations |
When kth iteration is completed, th data set is normal data set, |
1: Normalize data set and as |
2: Separate training, validation, and testing data at a certain rate |
3: Compute the variable importance using random forest, then sort in descending order |
4: Train supervised learning classifier using variables ranked in the top 10 |
5: Compute performance evaluation metrics and save result |
6: Iterate k processes |
Perform normality test on evaluation results (). |
Average evaluation results (): Alert if > 0.7, Alarm if > 0.8, Warning if > 0.9 |
Output: |
Alert, Alarm, Warning from normality test and averaged evaluation results |
4. Theoretical Background
4.1. Random Forest
- Bootstrap resampling is run k times on the original sample data set, thus collecting a fixed number of samples each time, taking them back out after each sampling, and then obtaining K subsample sets.
- The CART algorithm is used to generate a decision tree for each subsample set. If feature from the ith subsample set contains C categories, the Gini index is calculated as follows: In the case that the feature from the ith subsample set contains C categories, the Gini index is calculated as follows:
- Based on Step 2, each subsample set generates a decision tree, and the decision trees of all the subsample sets form a random forest. Each decision tree is pruned according to the minimum Gini criterion by automatically selecting M features from feature set T containing M features as the attribute separation.
- A majority voting algorithm is used to analyze and vote on the results of the final RF algorithm.
4.2. Support Vector Machines
4.3. Model Performance Evaluation Metrics
4.4. Feature Extraction
5. Experiment Validation
5.1. Data Acquisition and Preprocessing
5.2. Experiment Results
5.3. Normality Test for Classification Evaluation Metrics
5.4. Variable Importance and Partial Dependence Plot
6. Discussion and Conclusions
- It is still necessary to find the optimal combination of hyper parameters used in pseudolabel analysis, such as the interval between normal and abnormal data sets (d), the data set window size (w), and the movement interval (s).
- There is a need for research on a hybrid LM, which monitors equipment conditions with R-LM under normal conditions and switches to LM under abnormal conditiosn to monitor accumulated changes. The advantages of R-LM and LM will be combined if a hybrid LM is successfully developed.
- Research that predicts equipment condition changes and categorizes them according to their type can reduce false alarms and contribute to the diagnosis of equipment problems.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
Abbreviations
AE | Autoencoder |
AI | Artificial Intelligence |
BM | Breakdown Maintenance |
CART | Classification and Regression Tree |
CBM | Condition-Based Maintenance |
CNN | Convolutional Neural Networks |
DS | Drive Side |
FDD | Fault Detection and Diagnosis |
GPUs | Graphics Processing Units |
LM | Lagrange Method |
ML | Machine Learning |
NDS | Nondrive Side |
PDP | Partial Dependence Plot |
R-LM | Reduced Lagrange Method |
RF | Random Forest |
PM | Preventive Maintenance |
SVM | Support Vector Machine |
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Domain | Common Statistical Features | ||
---|---|---|---|
Time domain | |||
Domain | Common Statistical Features | ||
---|---|---|---|
Frequency domain | |||
Evaluation Metric | Kernel | Step 1 | Step 2 | Step 3 | Step 4 | Step 5 | Step 6 | Step 7 | Step 8 | Step 9 | Step 10 |
---|---|---|---|---|---|---|---|---|---|---|---|
Accuracy (DS) | Radial | 0.6189 | 0.6384 | 0.5870 | 0.5527 | 0.5847 | 0.5657 | 0.5703 | 0.5745 | 0.9898 | 0.7791 |
Linear | 0.6541 | 0.6842 | 0.5916 | 0.5587 | 0.6013 | 0.5578 | 0.5384 | 0.5518 | 0.9847 | 0.7800 | |
Sigmoid | 0.5921 | 0.6097 | 0.5486 | 0.5625 | 0.5671 | 0.5486 | 0.5601 | 0.5532 | 0.9671 | 0.7763 | |
Polynomial | 0.6111 | 0.6310 | 0.5842 | 0.5648 | 0.5717 | 0.5504 | 0.5578 | 0.5662 | 0.9833 | 0.7796 | |
Accuracy (NDS) | Radial | 0.7523 | 0.5740 | 0.5754 | 0.5421 | 0.6138 | 0.5893 | 0.5851 | 0.5564 | 0.9884 | 0.7861 |
Linear | 0.7476 | 0.5828 | 0.5712 | 0.5347 | 0.5949 | 0.5379 | 0.5370 | 0.5319 | 0.9921 | 0.7717 | |
Sigmoid | 0.6546 | 0.5555 | 0.5587 | 0.5555 | 0.5759 | 0.5620 | 0.5550 | 0.5657 | 0.9773 | 0.7819 | |
Polynomial | 0.6995 | 0.5675 | 0.5625 | 0.5486 | 0.5837 | 0.5995 | 0.5606 | 0.5657 | 0.9898 | 0.7819 | |
Precision (DS) | Radial | 0.6235 | 0.6407 | 0.5858 | 0.5568 | 0.5878 | 0.5716 | 0.5772 | 0.5786 | 0.9872 | 0.7796 |
Linear | 0.6667 | 0.6873 | 0.5889 | 0.5593 | 0.6224 | 0.5678 | 0.5427 | 0.5616 | 0.9791 | 0.7839 | |
Sigmoid | 0.5932 | 0.6113 | 0.5500 | 0.5638 | 0.5678 | 0.5498 | 0.5586 | 0.5557 | 0.9643 | 0.7777 | |
Polynomial | 0.6172 | 0.6440 | 0.5798 | 0.5640 | 0.5835 | 0.5537 | 0.5588 | 0.5664 | 0.9794 | 0.7823 | |
Precision (NDS) | Radial | 0.7620 | 0.5833 | 0.5788 | 0.5680 | 0.6202 | 0.5950 | 0.5883 | 0.5635 | 0.9830 | 0.7868 |
Linear | 0.7808 | 0.5815 | 0.5736 | 0.5344 | 0.6003 | 0.5412 | 0.5425 | 0.5286 | 0.9893 | 0.7753 | |
Sigmoid | 0.6643 | 0.5568 | 0.5624 | 0.5567 | 0.5799 | 0.5632 | 0.5586 | 0.5651 | 0.9640 | 0.7858 | |
Polynomial | 0.7226 | 0.5662 | 0.5619 | 0.5491 | 0.5871 | 0.6070 | 0.5620 | 0.5665 | 0.9916 | 0.7840 | |
Specificity (DS) | Radial | 0.6769 | 0.6722 | 0.6463 | 0.7120 | 0.6796 | 0.6602 | 0.6454 | 0.6315 | 0.9870 | 0.8148 |
Linear | 0.7176 | 0.7593 | 0.6694 | 0.6185 | 0.7176 | 0.6491 | 0.6472 | 0.6352 | 0.9778 | 0.8157 | |
Sigmoid | 0.6287 | 0.6454 | 0.5880 | 0.6167 | 0.6028 | 0.6111 | 0.5778 | 0.5917 | 0.9639 | 0.8028 | |
Polynomial | 0.6806 | 0.6954 | 0.6074 | 0.5870 | 0.6500 | 0.6176 | 0.6287 | 0.6380 | 0.9787 | 0.8306 | |
Specificity (NDS) | Radial | 0.7722 | 0.6796 | 0.6759 | 0.7426 | 0.6769 | 0.6481 | 0.6426 | 0.6259 | 0.9824 | 0.8222 |
Linear | 0.8157 | 0.6509 | 0.6463 | 0.5870 | 0.6824 | 0.6426 | 0.7380 | 0.5981 | 0.9889 | 0.8157 | |
Sigmoid | 0.6981 | 0.6028 | 0.6167 | 0.5954 | 0.6102 | 0.6065 | 0.6157 | 0.6009 | 0.9667 | 0.8130 | |
Polynomial | 0.7620 | 0.6194 | 0.6250 | 0.5861 | 0.6315 | 0.6602 | 0.6204 | 0.6046 | 0.9917 | 0.8259 | |
Sensitivity (DS) | Radial | 0.6528 | 0.6722 | 0.6926 | 0.7444 | 0.6639 | 0.6361 | 0.6361 | 0.6306 | 0.9963 | 0.8157 |
Linear | 0.7546 | 0.7685 | 0.6722 | 0.6454 | 0.6343 | 0.6250 | 0.6315 | 0.6500 | 0.9917 | 0.8176 | |
Sigmoid | 0.6491 | 0.6565 | 0.5926 | 0.6130 | 0.6204 | 0.5944 | 0.6241 | 0.5889 | 0.9759 | 0.8065 | |
Polynomial | 0.6806 | 0.6833 | 0.6500 | 0.5954 | 0.6296 | 0.6019 | 0.6333 | 0.6343 | 0.9880 | 0.8278 | |
Sensitivity (NDS) | Radial | 0.7454 | 0.6657 | 0.6120 | 0.7565 | 0.6898 | 0.6481 | 0.6583 | 0.5963 | 0.9954 | 0.8269 |
Linear | 0.7398 | 0.6463 | 0.6519 | 0.5935 | 0.6528 | 0.6009 | 0.6009 | 0.6546 | 0.9981 | 0.8213 | |
Sigmoid | 0.6537 | 0.5981 | 0.5769 | 0.5806 | 0.6009 | 0.5981 | 0.5833 | 0.6056 | 0.9991 | 0.8083 | |
Polynomial | 0.6944 | 0.6306 | 0.6481 | 0.5917 | 0.6157 | 0.6583 | 0.6222 | 0.6370 | 0.9917 | 0.8139 | |
Alarm Signal * | R-LM ** | A | At | At | N | At | N | N | N | W | A |
LM ** | A | A | A | A | A | N | N | N | W | A |
Sensor Position | Test Method | Step 1 | Step 2 | Step 3 | Step 4 | Step 5 | Step 6 | Step 7 | Step 8 | Step 9 | Step 10 |
---|---|---|---|---|---|---|---|---|---|---|---|
Drive Side | Shapiro–Wilk | 0.0003 | 0.0002 | 0.0000 | 0.2677 | 0.0070 | 0.6323 | 0.1888 | 0.0585 | 0.0000 | 0.0000 |
Anderson–D | 0.0094 | 0.0025 | 0.0038 | 0.2234 | 0.0736 | 0.5098 | 0.2506 | 0.2270 | 0.0000 | 0.0000 | |
Lilliefors | 0.0506 | 0.0067 | 0.0168 | 0.3623 | 0.2790 | 0.7019 | 0.0768 | 0.1874 | 0.0000 | 0.0000 | |
Nondrive Side | Shapiro–Wilk | 0.0000 | 0.2170 | 0.0156 | 0.6334 | 0.0001 | 0.7534 | 0.4786 | 0.7625 | 0.0000 | 0.0000 |
Anderson–D | 0.0000 | 0.1185 | 0.0951 | 0.3435 | 0.0038 | 0.6461 | 0.5703 | 0.6068 | 0.0000 | 0.0000 | |
Lilliefors | 0.0000 | 0.0926 | 0.0181 | 0.3217 | 0.0081 | 0.6831 | 0.5198 | 0.4042 | 0.0000 | 0.0000 | |
Alarm Signal | Normality test * | A | A | A | N | A | N | N | N | A | A |
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Seo, M.-K.; Yun, W.-Y. Gearbox Condition Monitoring and Diagnosis of Unlabeled Vibration Signals Using a Supervised Learning Classifier. Machines 2024, 12, 127. https://doi.org/10.3390/machines12020127
Seo M-K, Yun W-Y. Gearbox Condition Monitoring and Diagnosis of Unlabeled Vibration Signals Using a Supervised Learning Classifier. Machines. 2024; 12(2):127. https://doi.org/10.3390/machines12020127
Chicago/Turabian StyleSeo, Myung-Kyo, and Won-Young Yun. 2024. "Gearbox Condition Monitoring and Diagnosis of Unlabeled Vibration Signals Using a Supervised Learning Classifier" Machines 12, no. 2: 127. https://doi.org/10.3390/machines12020127