Search Results (1,858)

Reliable detection of faults in centrifugal pump systems is challenging in industrial environments due to harsh operating conditions, limited sensor access, and the need for fast, explainable decisions. We developed PumpSpectra, an industrial Motor Current Signature Analysis (MCSA) platform that processes uploaded stator-current CSV files using FFT/STFT with transparent, rule-based models designed to identify mechanical faults including misalignment, bearing defects, and impeller anomalies; field validation demonstrated misalignment detection. In a case study at the El Oued desalination plant (Algeria; $n=40$ operating points), PumpSpectra achieved 91.2% diagnostic accuracy with a 95% reduction in analysis time compared to manual MCSA post-processing, and a false-positive rate of 3.8% at 0.1 Hz resolution. These results suggest that current-only, explainable analytics can support predictive maintenance programs by accelerating fault triage, improving traceability of decisions, and reducing avoided maintenance costs in pump-driven industrial assets. Full article

Bearing fault diagnosis encounters limitations including insufficient accuracy, elevated model complexity, and demanding hyperparameter optimization. This research introduces a diagnostic framework combining variational mode decomposition (VMD) and fast Fourier transform (FFT) for extracting comprehensive temporal–spectral characteristics from vibration data. The methodology employs a hybrid deep learning architecture integrating convolutional neural networks (CNNs) with Transformers, where CNNs identify local features while Transformers capture extended dependencies. Meta-learning-enhanced Bayesian optimization and HyperBand (Meta-BOHB) is utilized for efficient hyperparameter selection. Evaluation on the Case Western Reserve University (CWRU) dataset using 5-fold cross-validation demonstrates a mean classification accuracy of 99.91% with exceptional stability (±0.08%). Comparative analysis reveals superior performance regarding precision, convergence rate, and loss metrics compared to existing approaches. Cross-dataset validation using Mechanical Fault Prevention Technology (MFPT) and Paderborn University (PU) datasets confirms robust generalization capabilities, achieving 100% and 98.75% accuracy within 5 and 7 iterations, respectively. Ablation studies validate the contribution of each component. Results demonstrate consistent performance across diverse experimental conditions, indicating significant potential for enhancing reliability and reducing operational costs in industrial fault diagnosis applications. The proposed method effectively addresses key challenges in bearing fault detection through advanced signal processing and optimized deep learning techniques. Full article

Against the backdrop of intelligent manufacturing, the ball mill, as a key energy-consuming piece of equipment, requires an accurate perception of its load state, which is crucial for optimizing production efficiency and ensuring operational safety. However, its vibration signals exhibit typical nonlinear and non-stationary characteristics, intertwined with complex noise, posing significant challenges to high-precision identification. A core contradiction exists in existing diagnostic methods: convolution network-based methods excel at capturing local features but overlook global trends, while Transformer-type models, although capable of capturing long-range dependencies, tend to “average out” critical local transient information during modeling. To address this dilemma, this paper proposes a new paradigm for multi-scale feature collaborative perception. This paradigm is implemented through an innovative deep learning architecture—the Residual Block-Swin Transformer Network (RB-SwinT). This architecture subtly achieves hierarchical and in-depth integration of the powerful global context modeling capability of Swin Transformer and the excellent local detail refinement capability of the residual module (ResBlock), enabling synchronous and efficient representation of both the macro trends and micro mutations of signals. On the experimental dataset covering nine types of fine operating conditions, the overall recognition accuracy of the proposed method reaches as high as 96.20%, which is significantly superior to a variety of mainstream models. To further verify the model’s generalization ability, this study was tested on the CWRU public bearing fault dataset, achieving a recognition accuracy of 99.36%, which outperforms various comparative methods such as SAVMD-CNN. This study not only provides a reliable new technical approach for ball mill load identification but also demonstrates its practical application value in indicating critical operating conditions and optimizing production operations through an in-depth analysis of the physical connotations of each load level. More importantly, its “global-local” collaborative modeling concept opens up a promising technical path for processing a broader range of complex industrial time-series data. Full article

The planetary bearing looseness fault can cause the planetary gear train to fail. Conventional modeling methods do not consider complex component-coupling relationships for fault feature analysis. As a result, a joint model is developed to examine the dominant relationship between planetary bearings and the planetary gear train. Firstly, the planetary bearing is modeled in the normal and fault states. Then, a refined joint planetary gear train dynamic model is constructed, which is composed of the planetary gears, the ring gear, the carrier, the sun gear, and the planetary bearings. Finally, the simulation results show that, when the planetary bearing is in the looseness fault state, its fault characteristic presents as the rotation frequency of the carrier and its harmonics. The on-site signal of a 2.0 MW wind turbine is used to verify the effectiveness of the model. The proposed model can provide the basis for the fault mechanism analysis and fault diagnosis of rolling bearing outer ring looseness. Full article

In bearing fault diagnosis for rotating machinery, multi-sensor data—such as acoustic and vibration signals—are increasingly leveraged to enhance diagnostic performance. However, existing methods often rely on complex network architectures and incur high computational costs, limiting their applicability in real-time industrial environments. To address these challenges, this study proposes a lightweight and efficient multi-sensor ensemble framework that achieves high diagnostic accuracy while minimizing computational overhead. The proposed method transforms vibration and acoustic signals into spectrograms, which are independently processed by modality-specific lightweight convolutional neural networks (CNNs). The softmax outputs from each classifier are integrated using an AdaBoost-based ensemble strategy that emphasizes high-confidence predictions and adapts to sensor-specific misclassification patterns. Experimental results on benchmark datasets—UORED-VAFCLS, KAIST, and an in-house bearing dataset—demonstrate an average classification accuracy exceeding 99.90%, with notable robustness against false positives and missed detections. Furthermore, the framework significantly reduces resource consumption in terms of FLOPs, inference latency, and model size compared to existing state-of-the-art multi-sensor fusion approaches. Overall, this work presents a practical and deployable solution for real-time bearing fault diagnosis, balancing classification performance with computational efficiency without resorting to complex feature fusion mechanisms. Full article

In real-world industrial settings, obtaining class-balanced fault data is often difficult. Imbalanced data across categories can degrade diagnostic accuracy. Time-series Generative Adversarial Network (TimeGAN) is an effective tool for addressing one-dimensional data imbalance; however, when dealing with multiple fault categories, it faces issues such as unstable training processes and uncontrollable generation states. To address this issue, from the perspective of data augmentation and classification, a gradient-penalized Conditional Time-series Generative Adversarial Network with a Multi-Scale Importance-aware Network (CTGAN-MSIN) is proposed in this paper. Firstly, a gradient-penalized Conditional Time-Series Generative Adversarial Network (CTGAN) is designed to alleviate data imbalance by controllably generating high-quality fault samples. Secondly, a Multi-scale Importance-aware Network (MSIN) is constructed for fault classification. The MSIN consists of the Multi-scale Depthwise Separable Residual (MDSR) and Scale Enhanced Local Attention (SELA): the MDSR network can efficiently extract multi-scale features, while the SELA network is capable of screening out the most discriminative scale features from them. Finally, the proposed method is validated using the HUST bearing dataset and the axial piston pump dataset. The results show that under the data imbalance ratio of 15:1, the CTGAN-MSIN achieves diagnostic accuracies of 98.75% and 96.50%, respectively, on the two datasets and outperforms the comparison methods under different imbalance ratios. Full article

This study introduces a sensorless fault diagnosis method for efficiently detecting bearing faults in induction motors. The proposed method eliminates the need for torque sensors, frequency sensors, thermal cameras, or real-time Fast Fourier Transform (FFT) tools. Induction motors are commonly utilized in a variety of industrial applications, including fans, pumps, and home appliances, due to their straightforward construction, affordability, and robust reliability. Traditional bearing fault diagnosis methods often rely on additional hardware such as vibration or thermal sensors. Additionally, approaches employing Artificial Intelligence (AI) and real-time FFT processing require advanced and expensive hardware capabilities. However, many V/f control systems are primarily intended for cost-effective and simple implementations, making resource-intensive approaches undesirable. Therefore, such methods present limitations for these use cases. To address these challenges, this paper presents a sensorless detection technique that estimates torque via a flux observer, removing the dependence on external sensors. The estimated torque is processed using an offline FFT to identify amplitude changes within bearing fault frequency bands. Here, the FFT-based frequency analysis is performed offline and is used to design a targeted band-pass filter (BPF). The torque signal, after passing through the BPF, undergoes a straightforward threshold-based logic to assess the existence of faults. Compared to AI- or data-driven approaches, the proposed method provides a lightweight, interpretable, and sensorless solution without the need for additional training or high-end processors. Despite its straightforward approach, the technique achieves effective detection of bearing faults across various components and speeds, making it ideal for embedded and economically constrained motor applications. Full article

Conventional signal-to-image conversion methods often overlook the physical correspondence of vibration signals, limiting diagnostic interpretability. To address this, we propose a physics-guided image construction strategy that incorporates dimensionless indicators to adaptively weight grayscale regions, enhancing the physical consistency and the discriminability among different fault types. Furthermore, a novel Cheap Channel Obfuscation module is introduced to suppress noise, decouple feature channels, and preserve the critical information within lightweight models. Integrated with ShuffleNetV2, our method achieves high diagnostic accuracy. Experimental validation for CWRU and SEU bearing datasets yields accuracies of 100% and 99.91%, respectively, demonstrating superior performance with minimal parameters. This approach offers a technically robust and computationally efficient fault diagnosis solution, with promising potential for deployment in resource-limited industrial environments. Full article

Water inrush disasters pose a serious threat during tunnel construction. Accurately evaluating their evolution process is essential for timely prevention and risk mitigation. Given the staged nature of seepage-instability-induced inrushes and the sensitivity of borehole resistivity imaging to water-bearing anomalies, this study explores the use of borehole resistivity methods to monitor the evolution of such events. A four-stage geoelectrical evolution model is developed based on the characteristics of inclined fault-related water inrushes. A time-lapse evaluation method combining least squares inversion and resistivity ratio analysis is proposed to assess the inrush process. Numerical simulations show that this method achieves a localization error below 2 m for inclined water-conducting channels. Across the four stages, the resistivity ratio of the channel ranges from 0.65 to 1.40, capturing the three-dimensional expansion of the inrush pathway. These findings confirm that borehole resistivity imaging effectively characterizes the evolution of water inrush disasters and supports early warning and mitigation strategies. Full article

Gallium (Ga) enrichment in sphalerite has been widely recognized; however, its enrichment mechanisms remain insufficiently understood. The South Hunan district, located at the intersection of the Nanling Region and the Qin-Hang Metallogenic Belt in South China, is characterized by abundant Jurassic magmatic-hydrothermal Pb–Zn deposits, which typically host Ga-depleted sphalerite. Recently, Ga-enriched sphalerite (up to 385 ppm by LA-ICP-MS) has been identified in newly drilled cores at Zhaojinci, adding complexity to the regional Pb–Zn metallogenic framework. EPMA elemental mapping and LA-ICP-MS time-resolved spectra indicate that Ga is homogeneously distributed within sphalerite, excluding the presence of micron-scale Ga-bearing mineral inclusions. A strong positive correlation between Ga and Cu concentrations suggests that Ga incorporation is facilitated by the coupled substitution of Zn²⁺ by Cu⁺. Sphalerite geothermometry yields formation temperatures of 118–138 °C (average 126 °C for GGIMF is and ~129 °C for SPRFT), accompanied by intermediate sulfur fugacity conditions (lg fS₂ = −22.9 to −21.2), which appear to favor Ga enrichment in sphalerite. The trace element geochemistry of the Zhaojinci sphalerite (Ga-Ge-Cd-enriched and Mn-In-Sn-Co-depleted), combined with its formation under low-temperature (120–180 °C) and intermediate fS₂ conditions (within the pyrite stability field), is consistent with MVT-like mineralization. This interpretation is supported by multiple lines of geological evidence, including the strict confinement of stratabound Pb–Zn mineralization to the Devonian Xikuangshan Formation limestone, structural control by syn-sedimentary normal faults, pervasive dolomitization of the host rocks, and the absence of genetic relationship to magmatic activity. Moreover, the sphalerite geochemical signature, corroborated by an XGBoost-based machine learning classifier, reinforce the MVT-like affinity for the Zhaojinci mineralization. This study not only emphasizes the importance of low-temperature and intermediate-fS₂ conditions in Ga enrichment within sphalerite, but also highlights the significance of discovering MVT-like sphalerite for Pb–Zn resource exploration in the South Hunan district, providing valuable new insights and directions for mineral prospecting in this geologically important region of South China. Full article

This paper presents a fault diagnosis model for rolling bearings that addresses the challenges of establishing long-sequence correlations and extracting spatial features in deep-learning models. The proposed model combines SENet with an improved Informer model. Initially, local features are extracted using the Conv1d method, and input data is optimized through normalization and embedding techniques. Next, the SE-Conv1d network model is employed to enhance key features while suppressing noise interference adaptively. In the improved Informer model, the ProbSparse self-attention mechanism and self-attention distillation technique efficiently capture global dependencies in long sequences within the rolling bearing dataset, significantly reducing computational complexity and improving accuracy. Finally, experiments on the CWRU and HUST datasets demonstrate that the proposed model achieves accuracy rates of 99.78% and 99.45%, respectively. The experimental results show that, compared to other deep learning methods, the proposed model offers superior fault diagnosis accuracy, stability, and generalization ability. Full article

Rolling bearings are critical components in mechanical systems, and their health directly affects operational reliability and safety. However, their exposure to harsh conditions makes accurate fault diagnosis essential. Conventional methods relying on expert knowledge and handcrafted features are inefficient, while deep learning still suffers from data imbalance, which limits generalization. To address this challenge, an Attention-Enhanced Conditional Wasserstein GAN (ACWGAN) is proposed, in which the attention mechanism is incorporated into both the generator and discriminator to capture global dependencies and enhance feature diversity. By combining attention guidance with the Wasserstein distance, the framework achieves more stable training, alleviates mode collapse, and generates high-fidelity fault samples to balance imbalanced datasets. Compared with existing GAN-based methods, this method, combined with wavelet-based ResNet, significantly improves the accuracy of diagnosis, achieving 100% accuracy in the generated dataset. Full article

Metal components such as rolling bearings are prone to wear, cracks, and defects in harsh environments and long-term use, leading to performance degradation and potential equipment failures. Therefore, detecting surface cracks and other defects in rolling bearings is of great significance for ensuring equipment reliability and safety. However, traditional signal decomposition methods like EEMD and FEEMD suffer from residual noise and mode mixing issues, while deconvolution algorithms such as CYCBD are sensitive to parameter settings and struggle in high-noise environments. To mitigate the susceptibility of fault signals to background noise interference, this paper proposes a fault feature extraction method based on fast complementary ensemble empirical mode decomposition (FCEEMD) and adaptive maximum second-order cyclostationarity blind deconvolution (ACYCBD). Firstly, we propose FCEEMD, which effectively eliminates the residual noise of ensemble empirical mode decomposition (EEMD) and fast ensemble empirical mode decomposition (FEEMD) by introducing paired white noise with opposite signs, solving the problems of traditional decomposition methods that are greatly affected by noise, having large reconstruction errors, and being high time-consuming. Subsequently, a new intrinsic mode function (IMF) screening index based on correlation coefficients and energy kurtosis is developed to effectively mitigate noise influence and enhance the quality of signal reconstruction. Secondly, the ACYCBD model is constructed, and the hidden periodic frequency is detected by the enhanced Hilbert phase synchronization (EHPS) estimator, which significantly enhances the extraction effect of the real periodic fault features in the noise. Finally, instantaneous energy tracking of bearing fault characteristic frequency is achieved through Teager energy operator demodulation, thereby accurately extracting fault state features. The experiment shows that the proposed method accurately extracts the fault characteristic frequencies of 164.062 Hz for inner ring faults and 105.469 Hz for outer ring faults, confirming its superior accuracy and efficiency in rolling bearing fault diagnosis. Full article

This study addresses the condition monitoring of rolling bearings by applying robust linear regression to statistically derived features from vibration data. Four datasets of acceleration signals were collected under varying operating conditions: aligned and misaligned bearings at rotational speeds of 1000 rpm and 1500 rpm. From each signal, key statistical indicators were extracted, including root mean square (RMS), skewness, kurtosis and crest factor, to capture signal characteristics that were relevant to fault detection. To follow-up, we applied the Kolmogorov–Smirnov test to assess data normality and the results confirmed significant deviations from a Gaussian distribution, motivating the use of robust regression techniques for further investigations. The regression model created incorporated rotational speed and alignment conditions as predictors of acceleration and the results indicated that while the coefficient associated with misalignment suggested a possible increase in acceleration (~1.115 units), statistical testing (p = 0.5233) indicated that neither speed nor alignment had a significant influence on the measured vibration levels within the dataset. The findings suggest that under the tested conditions, misalignment does not manifest as a strong linear change in acceleration magnitude, and the study underscores the importance of robust modeling techniques and feature selection in the condition monitoring of rotating machinery. Full article

This study systematically analyzes the dynamic behavior of bearing tilt-misalignment coupling faults in rotary joints and establishes a high-fidelity nonlinear dynamic model for a dual-support bearing–rotor system. By integrating Hertzian contact theory, the nonlinear contact forces induced by the tilt of the inner/outer rings and axial misalignment are considered, and expressions for bearing forces incorporating time-varying stiffness and radial clearance are derived. The system’s vibration response is solved using the Newmark-β numerical integration method. This study reveals the influence of tilt angle and misalignment magnitude on contact forces, vibration patterns, and fault characteristic frequencies, demonstrating that the system exhibits multi-frequency harmonic characteristics under misalignment conditions, with vibration amplitudes increasing nonlinearly with the degree of misalignment. Furthermore, dynamic models for single-point faults (inner/outer ring) and composite faults are constructed, and Gaussian filtering technology is employed to simulate defect surface roughness, analyzing the modulation effects of faults on spectral characteristics. Experimental validation confirms that the theoretical model effectively captures actual vibration features, providing a theoretical foundation for health monitoring and intelligent diagnosis of rotary joints. Full article