Data-Driven Fault Diagnosis for Machines and Systems

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Machines Testing and Maintenance".

Deadline for manuscript submissions: 30 April 2025 | Viewed by 3923

Special Issue Editors


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Guest Editor
1. Adjunct Professor, Department of Mathematics and Industrial Engineering, Polytechnique Montréal, Montréal, QC H3T 1J4, Canada
2. Research Scientist, CanmetENERGY-Natural Resources Canada, Varennes, QC J3X 1P7, Canada
Interests: artificial intelligence (AI); fault diagnosis & prognosis; reliability analysis and maintenance management; process mining; supervisory control theory; discrete event systems modeling

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Guest Editor
Project Manager, CanmetENERGY-Natural Resources Canada, Varennes, QC J3X 1P7, Canada
Interests: hybrid process modeling, simulation, and optimization; abnormal events detection and diagnosis; control systems engineering; chemical processes design and operation; energy performance improvement; energy technology transfer and commercialization

Special Issue Information

Dear Colleagues,

The Industrial Internet of Things (IIoT), big data analytics, and artificial intelligence (AI) have significantly transformed the realm of fault diagnosis and prognosis in industrial systems and machinery. This transformation has led to the optimization of production processes, improved quality control, and reduced downtime. Compared to traditional methods, data-driven fault diagnosis offers a more precise and efficient approach, capable of adapting to system behavior changes over time. Despite these advancements, the complexity of modern systems and the escalating need for productivity and efficiency continue to present challenges and opportunities for further research in this area.

The proposed Special Issue aims to cover the latest advancements and challenges in data-driven fault diagnosis and prognosis, including the following:

  • Novel approaches for data preprocessing, feature extraction, and feature selection;
  • Advanced ML algorithms for fault detection, isolation, and classification;
  • Online and real-time fault diagnosis and prognosis techniques;
  • Hybrid (physics-based and data-driven) models for fault diagnosis;
  • Integration of ML-based fault diagnosis with other smart manufacturing technologies;
  • Case studies and applications in different industrial domains such as manufacturing, energy, transportation, and others.

The target audience includes researchers and practitioners in ML, data analytics, industrial engineering, and chemical engineering.

The Special Issue will focus on recent advances in three main directions in ML-based fault detection and diagnosis, including the following:

  • Deep learning: This Special Issue will explore the latest developments in this area, including the use of convolutional neural networks (CNNs), recurrent neural networks (RNNs), and generative adversarial networks (GANs).
  • Explainable AI: The interpretability of machine learning models is a critical issue in industrial fault diagnosis, where decisions can have significant economic and safety implications. This Special Issue will explore recent work on developing explainable AI methods for fault diagnosis, such as rule extraction and feature importance analysis.
  • Physics-based deep learning (DL): This is a growing approach that integrates the principles of physics into the design and training of deep learning models. This Special Issue aims to illuminate how this approach contributes to enhancing the effectiveness, interpretability, and reliability of fault detection and diagnosis in machines and systems.
  • Transfer learning: Transfer learning is a promising approach for leveraging pre-trained models to improve the performance of fault diagnosis in new domains or with limited data. This Special Issue will investigate recent advances in transfer learning for fault diagnosis in industrial systems and machines.

Dr. Ahmed Ragab
Dr. Mouloud Amazouz
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Machines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • fault diagnosis and prognosis
  • data-driven modeling
  • condition monitoring
  • predictive maintenance
  • anomaly detection
  • decision support systems
  • causality analysis
  • root cause analysis

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Published Papers (4 papers)

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Research

18 pages, 3640 KiB  
Article
Fault Diagnosis in Drones via Multiverse Augmented Extreme Recurrent Expansion of Acoustic Emissions with Uncertainty Bayesian Optimisation
by Tarek Berghout and Mohamed Benbouzid
Machines 2024, 12(8), 504; https://doi.org/10.3390/machines12080504 - 26 Jul 2024
Viewed by 517
Abstract
Drones are a promising technology performing various functions, ranging from aerial photography to emergency response, requiring swift fault diagnosis methods to sustain operational continuity and minimise downtime. This optimises resources, reduces maintenance costs, and boosts mission success rates. Among these methods, traditional approaches [...] Read more.
Drones are a promising technology performing various functions, ranging from aerial photography to emergency response, requiring swift fault diagnosis methods to sustain operational continuity and minimise downtime. This optimises resources, reduces maintenance costs, and boosts mission success rates. Among these methods, traditional approaches such as visual inspection or manual testing have long been utilised. However, in recent years, data representation methods, such as deep learning systems, have achieved significant success. These methods learn patterns and relationships, enhancing fault diagnosis, but also face challenges with data complexity, uncertainties, and modelling complexities. This paper tackles these specific challenges by introducing an efficient representation learning method denoted Multiverse Augmented Recurrent Expansion (MVA-REX), allowing for an iterative understanding of both learning representations and model behaviours and gaining a better understanding of data dependencies. Additionally, this approach involves Uncertainty Bayesian Optimisation (UBO) under Extreme Learning Machine (ELM), a lighter neural network training tool, to tackle both uncertainties in data and reduce modelling complexities. Three main realistic datasets recorded based on acoustic emissions are involved in tackling propeller and motor failures in drones under realistic conditions. The UBO-MVA Extreme REX (UBO-MVA-EREX) is evaluated under many, error metrics, confusion matrix metrics, computational cost metrics, and uncertainty quantification based on both confidence and prediction interval features. Application compared to the well-known long-short term memory (LSTM), under Bayesian optimisation of the approximation error, demonstrates performances, certainty, and cost efficiency of the proposed scheme. More specifically, the accuracy obtained by UBO-MVA-EREX, ~0.9960, exceeds the accuracy of LSTM, ~0.9158, by ~8.75%. Besides, the search time for UBO-MVA-EREX is ~0.0912 s, which is ~98.15% faster than LSTM, ~4.9287 s, making it highly applicable for such challenging tasks of fault diagnosis-based acoustic emission signals of drones. Full article
(This article belongs to the Special Issue Data-Driven Fault Diagnosis for Machines and Systems)
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20 pages, 8172 KiB  
Article
Incipient Inter-Turn Short Circuit Detection in Induction Motors Using Cumulative Distribution Function and the EfficientNetv2 Model
by Carlos Javier Morales-Perez, Laritza Perez-Enriquez, Juan Pablo Amezquita-Sanchez, Jose de Jesus Rangel-Magdaleno, Martin Valtierra-Rodriguez and David Granados-Lieberman
Machines 2024, 12(6), 399; https://doi.org/10.3390/machines12060399 - 12 Jun 2024
Viewed by 574
Abstract
Induction motors are one of the most used machines because they provide the necessary traction force for many industrial applications. Their easy operation, installation, maintenance, and reliability make them preferred over other electrical motors. Mechanical and electrical failures, as with other machines, can [...] Read more.
Induction motors are one of the most used machines because they provide the necessary traction force for many industrial applications. Their easy operation, installation, maintenance, and reliability make them preferred over other electrical motors. Mechanical and electrical failures, as with other machines, can appear at any stage of their service life, making the stator intern-turn short-circuit fault (ITSC) stand out. Hence, its detection is necessary in order to extend and save useful life, avoiding a breakdown and unprogrammed maintenance processes as well as, in the worst circumstances, a total loss of the machine. Nonetheless, the challenge lies in detecting this type of fault, which has made the analysis and diagnosis processes easier. Such is the case with convolutional neural networks (CNNs), which facilitate the development of methodologies for pattern recognition in several areas of knowledge. Unfortunately, these techniques require a large amount of data for an adequate training process, which is not always available. In this sense, this paper presents a new methodology for the detection of incipient ITSC faults employing a modified cumulative distribution function (CDF) of the current stator signal. Then, these are converted to images and fed into a fast and compact CNN model, trained with a small data set, reaching up to 99.16% accuracy for seven conditions (0, 5, 10, 15, 20, 30, and 40 short-circuited turns) and four mechanical load conditions. Full article
(This article belongs to the Special Issue Data-Driven Fault Diagnosis for Machines and Systems)
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17 pages, 39084 KiB  
Article
Early-Stage ISC Fault Detection for Ship Lithium Batteries Based on Voltage Variance Analysis
by Yu Gu, Haishen Ni and Yuwei Li
Machines 2024, 12(5), 303; https://doi.org/10.3390/machines12050303 - 30 Apr 2024
Cited by 1 | Viewed by 734
Abstract
With the progressive development of new energy technologies, high-power lithium batteries have been widely used in ship power systems due to their high-power density and low environmental pollution, and they have gradually become one of their main propulsion energy sources. However, the large-scale [...] Read more.
With the progressive development of new energy technologies, high-power lithium batteries have been widely used in ship power systems due to their high-power density and low environmental pollution, and they have gradually become one of their main propulsion energy sources. However, the large-scale deployment of lithium batteries has also brought a series of safety problems to ship operations, especially the battery internal short circuit (ISC). Battery ISC faults are very hidden and unpredictable at the initial stage and often fail to be detected in time, ultimately leading to overheating, fire or even an explosion of the ship’s power system. Based on this, this paper proposes a fast and accurate method for early-stage ISC fault location and detection of lithium batteries. Initially, voltage variations across the lithium battery packs are quantified using curvilinear Manhattan distances to pinpoint faulty battery units. Subsequently, the localized characteristics of voltage variance among adjacent batteries are leveraged to detect an early-stage ISC fault. Simulation results indicate that the proposed method can quickly and accurately locate the position of 5 Ω, 10 Ω and 15 Ω ISC faulty batteries within the battery pack, as well as detect the abnormal batteries in a timely manner with considerable sensitivity and reliability. Full article
(This article belongs to the Special Issue Data-Driven Fault Diagnosis for Machines and Systems)
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19 pages, 3172 KiB  
Article
Transfer Learning Based Fault Detection for Suspension System Using Vibrational Analysis and Radar Plots
by Samavedam Aditya Sai, Sridharan Naveen Venkatesh, Seshathiri Dhanasekaran, Parameshwaran Arun Balaji, Vaithiyanathan Sugumaran, Natrayan Lakshmaiya and Prabhu Paramasivam
Machines 2023, 11(8), 778; https://doi.org/10.3390/machines11080778 - 26 Jul 2023
Cited by 10 | Viewed by 1463
Abstract
The suspension system is of paramount importance in any automobile. Thanks to the suspension system, every journey benefits from pleasant rides, stable driving and precise handling. However, the suspension system is prone to faults that can significantly impact the driving quality of the [...] Read more.
The suspension system is of paramount importance in any automobile. Thanks to the suspension system, every journey benefits from pleasant rides, stable driving and precise handling. However, the suspension system is prone to faults that can significantly impact the driving quality of the vehicle. This makes it essential to find and diagnose any faults in the suspension system and rectify them immediately. Numerous techniques have been used to identify and diagnose suspension faults, each with drawbacks. This paper’s proposed suspension fault detection system aims to detect these faults using deep transfer learning techniques instead of the time-consuming and expensive conventional methods. This paper used pre-trained networks such as Alex Net, ResNet-50, Google Net and VGG16 to identify the faults using radar plots of the vibration signals generated by the suspension system in eight cases. The vibration data were acquired using an accelerometer and data acquisition system placed on a test rig for eight different test conditions (seven faulty, one good). The deep learning model with the highest accuracy in identifying and detecting faults among the four models was chosen and adopted to find defects. The results state that VGG16 produced the highest classification accuracy of 96.70%. Full article
(This article belongs to the Special Issue Data-Driven Fault Diagnosis for Machines and Systems)
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