Single and combined fault diagnosis of reciprocating compressor valves using a hybrid deep belief network (original) (raw)
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Expert Systems with Applications, 2014
This paper presents an approach to implement vibration, pressure, and current signals for fault diagnosis of the valves in reciprocating compressors. Due to the complexity of structure and motion of such compressor, the acquired vibration signal normally involves transient impacts and noise. This causes the useful information to be corrupted and difficulty in accurately diagnosing the faults with traditional methods. To reveal the fault patterns contained in this signal, the Teager-Kaiser energy operation (TKEO) is proposed to estimate the amplitude envelopes. In case of pressure and current, the random noise is removed by using a denoising method based on wavelet transform. Subsequently, statistical measures are extracted from all signals to represent the characteristics of the valve conditions. In order to classify the faults of compressor valves, a new type of learning architecture for deep generative model called deep belief networks (DBNs) is applied. DBN employs a hierarchical structure with multiple stacked restricted Boltzmann machines (RBMs) and works through a greedy layer-by-layer learning algorithm. In pattern recognition research areas, DBN has proved to be very effective and provided with high performance for binary values. However, for implementing DBN to fault diagnosis where most of signals are real-valued, RBM with Bernoulli hidden units and Gaussian visible units is considered in this study. The proposed approach is validated with the signals from a two-stage reciprocating air compressor under different valve conditions. To confirm the superiority of DBN in fault classification, its performance is compared with that of relevant vector machine and back propagation neuron networks. The achieved accuracy indicates that the proposed approach is highly reliable and applicable in fault diagnosis of industrial reciprocating machinery.
A Deep Learning Approach for Fault Diagnosis of Induction Motors in Manufacturing
Chinese Journal of Mechanical Engineering
Extracting features from original signals is a key procedure for traditional fault diagnosis of induction motors, as it directly influences the performance of fault recognition. However, high quality features need expert knowledge and human intervention. In this paper, a deep learning approach based on deep belief networks (DBN) is developed to learn features from frequency distribution of vibration signals with the purpose of characterizing working status of induction motors. It combines feature extraction procedure with classification task together to achieve automated and intelligent fault diagnosis. The DBN model is built by stacking multiple-units of restricted Boltzmann machine (RBM), and is trained using layer-bylayer pre-training algorithm. Compared with traditional diagnostic approaches where feature extraction is needed, the presented approach has the ability of learning hierarchical representations, which are suitable for fault classification, directly from frequency distribution of the measurement data. The structure of the DBN model is investigated as the scale and depth of the DBN architecture directly affect its classification performance. Experimental study conducted on a machine fault simulator verifies the effectiveness of the deep learning approach for fault diagnosis of induction motors. This research proposes an intelligent diagnosis method for induction motor which utilizes deep learning model to automatically learn features from sensor data and realize working status recognition.
Development of Deep Belief Network for Tool Faults Recognition
Sensors
The controlled interaction of work material and cutting tool is responsible for the precise outcome of machining activity. Any deviation in cutting parameters such as speed, feed, and depth of cut causes a disturbance to the machining. This leads to the deterioration of a cutting edge and unfinished work material. Recognition and description of tool failure are essential and must be addressed using intelligent techniques. Deep learning is an efficient method that assists in dealing with a large amount of dynamic data. The manufacturing industry generates momentous information every day and has enormous scope for data analysis. Most intelligent systems have been applied toward the prediction of tool conditions; however, they must be explored for descriptive analytics for on-board pattern recognition. In an attempt to recognize the variation in milling operation leading to tool faults, the development of a Deep Belief Network (DBN) is presented. The network intends to classify in tota...
Reciprocating compressors are widely used in industry for various purposes and faults occurring in them can degrade performance, consume additional energy, and even cause severe damage to the machine. This paper will develop an automated approach to condition classification of a reciprocating compressor based on vibration measurements. Both the time domain and frequency domain techniques have been applied to the vibration signals and a large number of candidate features have been obtained based on previous studies. A subset selection method has then been used to configure a probabilistic neural network (PNN), with high computational efficiency, for effective fault classifications. The results show that a 95.50% correct classification between four different faulty cases is the best result when using a subset of frequency feature, whereas a 93.05% rate is the best for the subset from the time domain.
Journal of Physics: Conference Series, 2011
Reciprocating compressors are widely used in industry for various purposes and faults occurring in them can degrade their performance, consume additional energy and even cause severe damage to the machine. Vibration monitoring techniques are often used for early fault detection and diagnosis, but it is difficult to prescribe a given set of effective diagnostic features because of the wide variety of operating conditions and the complexity of the vibration signals which originate from the many different vibrating and impact sources. This paper studies the use of genetic algorithms (GAs) and neural networks (NNs) to select effective diagnostic features for the fault diagnosis of a reciprocating compressor. A large number of common features are calculated from the time and frequency domains and envelope analysis. Applying GAs and NNs to these features found that envelope analysis has the most potential for differentiating three common faults: valve leakage, inter-cooler leakage and a loose drive belt. Simultaneously, the spread parameter of the probabilistic NN was also optimised. The selected subsets of features were examined based on vibration source characteristics. The approach developed and the trained NN are confirmed as possessing general characteristics for fault detection and diagnosis.
Research on the Classification Ability of Deep Belief Networks on Small and Medium Datasets
Recent theoretical advances in the learning of deep artificial neural networks have made it possible to overcome a vanishing gradient problem. This limitation has been overcome using a pre-training step, where deep belief networks formed by the stacked Restricted Boltzmann Machines perform unsupervised learning. Once a pre-training step is done, network weights are fine-tuned using regular error back propagation while treating network as a feed-forward net. In the current paper we perform the comparison of described approach and commonly used classification approaches on some well-known classification data sets from the UCI repository as well as on one mid-sized proprietary data set.
Detection of Valve Leakage in Reciprocating Compressor Using Artificial Neural Network (ANN)
2008
In the present work, Artificial Neural Networks (ANN) techniques are being applied for detection of valve leakage in reciprocating compressor. It has been experienced that replacement of defective valves before they cause further damage can greatly reduce maintenance and production costs. In the past, valve problems were unnoticed until process flow instruments showed a reduction in flow or when compressors became noisy or overheated. These symptoms usually did not occur until the very last stages of valve degradation. By this time the compressor frequently was damaged because of valve parts were being ingested into the cylinder and thus causing piston ring or liner damage. The application of Artificial Neural Networks technique identifies the most practical yet sensitive form of signature to use for trend monitoring and will additionally help the system to accept the fact that a compressor is malfunctioning without the aid of additional instruments capable of establishing credibility.
Annual Conference of the PHM Society
Rolling element bearings are critical components in industrial rotating machines. Faults and failures of bearings can cause degradation of machine performance or even a catastrophe. Bearing fault diagnosis is therefore essential and significant to safe and reliable operation of systems. For bearing condition monitoring, acoustic emission (AE) signals attract more and more attention due to its advantages on sensitivity over the extensively used vibration signal. In bearing fault diagnosis and prognosis, feature extraction is a critical and tough work, which always involves complex signal processing and computation. Moreover, features greatly rely on the characteristics, operating conditions, and type of data. With consideration of changes in operating conditions and increase of data complexity, traditional diagnosis approaches are insufficient in feature extraction and fault diagnosis. To address this problem, this paper proposes a Deep Belief Network (DBN) and Principal Component An...
2022
Deep learning and big data algorithms have become widely used in industrial applications to optimize several tasks in many complex systems. Particularly, deep learning model for diagnosing and prognosing machinery health has leveraged predictive maintenance (PdM) to be more accurate and reliable in decision making, in this way avoiding unnecessary interventions, machinery accidents, and environment catastrophes. Recently, Transformer Neural Networks have gained notoriety and have been increasingly the favorite choice for Natural Language Processing (NLP) tasks. Thus, given their recent major achievements in NLP, this paper proposes the development of an automatic fault classifier model for predictive maintenance based on a modified version of the Transformer architecture, namely T4PdM, to identify multiple types of faults in rotating machinery. Experimental results are developed and presented for the MaFaulDa and CWRU databases. T4PdM was able to achieve an overall accuracy of 99.98% and 98% for both datasets, respectively. In addition, the performance of the proposed model is compared to other previously published works. It has demonstrated the superiority of the model in detecting and classifying faults in rotating industrial machinery. Therefore, the proposed Transformer-based model can improve the performance of machinery fault analysis and diagnostic processes and leverage companies to a new era of the Industry 4.0. In addition, this methodology can be adapted to any other task of time series classification.
Intelligent diagnosis of petroleum equipment faults using a deep hybrid model
SN Applied Sciences
Performance assessment and timely failure detection of the electric submersible pump can reduce operation costs and maintenance in the oil and gas field. Features of equipment malfunction are changes in vibration signals. Evaluation of vibrations based on accelerometer sensors can detect failures and allows assessment of system failures. This paper proposes a reliable deep learning-based method for electric submersible pump faults detection. The frequency, time and spectral information of the vibrational signal are considered as input to the deep hybrid model. The spectral information includes the spectrogram obtained using the short-time Fourier transform and the scalogram as a result of the continuous wavelet transform and provides a detailed study of the vibration signal. The proposed approach is compared with k-nearest neighbors, support vector machines, logistic regression, and random forest. The experimental evaluation shows that the proposed deep hybrid model is superior to these machine learning methods, and can automatically and simultaneously detect failures of the electric submersible pump according to the vibration signal that is generated during system operation. The proposed approach gives good results and can help an expert in automatic diagnostics of equipment and several complex technical systems. Fig. 5 ROC curves of assessing the classification accuracy of the considered methods for five classes: faulty sensor (SENS), normal operational condition (NORM), unbalance (UNB), misalignment (MIS) and rubbing (RUB)