Daily Papers

Diagnosis of bearing faults is paramount to reducing maintenance costs and operational breakdowns. Bearing faults are primary contributors to machine vibrations, and analyzing their signal morphology offers insights into their health status. Unfortunately, existing approaches are optimized for controlled environments, neglecting realistic conditions such as time-varying rotational speeds and the vibration's non-stationary nature. This paper presents a fusion of time-frequency analysis and deep learning techniques to diagnose bearing faults under time-varying speeds and varying noise levels. First, we formulate the bearing fault-induced vibrations and discuss the link between their non-stationarity and the bearing's inherent and operational parameters. We also elucidate quadratic time-frequency distributions and validate their effectiveness in resolving distinctive dynamic patterns associated with different bearing faults. Based on this, we design a time-frequency convolutional neural network (TF-CNN) to diagnose various faults in rolling-element bearings. Our experimental findings undeniably demonstrate the superior performance of TF-CNN in comparison to recently developed techniques. They also assert its versatility in capturing fault-relevant non-stationary features that couple with speed changes and show its exceptional resilience to noise, consistently surpassing competing methods across various signal-to-noise ratios and performance metrics. Altogether, the TF-CNN achieves substantial accuracy improvements up to 15%, in severe noise conditions.

Detection of rolling-element bearing faults is crucial for implementing proactive maintenance strategies and for minimizing the economic and operational consequences of unexpected failures. However, many existing techniques are developed and tested under strictly controlled conditions, limiting their adaptability to the diverse and dynamic settings encountered in practical applications. This paper presents an efficient real-time convolutional neural network (CNN) for diagnosing multiple bearing faults under various noise levels and time-varying rotational speeds. Additionally, we propose a novel Fisher-based spectral separability analysis (SSA) method to elucidate the effectiveness of the designed CNN model. We conducted experiments on both healthy bearings and bearings afflicted with inner race, outer race, and roller ball faults. The experimental results show the superiority of our model over the current state-of-the-art approach in three folds: it achieves substantial accuracy gains of up to 15.8%, it is robust to noise with high performance across various signal-to-noise ratios, and it runs in real-time with processing durations five times less than acquisition. Additionally, by using the proposed SSA technique, we offer insights into the model's performance and underscore its effectiveness in tackling real-world challenges.

Three-phase asynchronous motor are fundamental components in industrial systems, and their failure can lead to significant operational downtime and economic losses. Vibration and current signals are effective indicators for monitoring motor health and diagnosing faults. However, motors in real applications often operate under variable conditions such as fluctuating speeds and loads, which complicate the fault diagnosis process. This paper presents a comprehensive dataset collected from a three-phase asynchronous motor under various fault types and severities, operating under diverse speed and load conditions. The dataset includes both single faults and mechanical-electrical compound faults, such as rotor unbalance, stator winding short circuits, bearing faults, and their combinations. Data were acquired under both steady and transitional conditions, with signals including triaxial vibration, three-phase currents, torque, and key-phase signals. This dataset supports the development and validation of robust fault diagnosis methods for electric motors under realistic operating conditions.

Current Cyber-Physical Systems (CPS) integrated with Digital Twin (DT) technology face critical limitations in achieving real-time performance for mission-critical industrial applications. Existing 5G-enabled systems suffer from latencies exceeding 10ms, which are inadequate for applications requiring sub-millisecond response times, such as autonomous industrial control and predictive maintenance. This research aims to develop and validate a 6G-enabled Digital Twin framework that achieves ultra-low latency communication and real-time synchronization between physical industrial assets and their digital counterparts, specifically targeting bearing fault detection as a critical industrial use case. The proposed framework integrates terahertz communications (0.1-1 THz), intelligent reflecting surfaces, and edge artificial intelligence within a five-layer architecture. Experimental validation was conducted using the Case Western Reserve University (CWRU) bearing dataset, implementing comprehensive feature extraction (15 time and frequency domain features) and Random Forest classification algorithms. The system performance was evaluated against traditional WiFi-6 and 5G networks across multiple metrics, including classification accuracy, end-to-end latency, and scalability. It achieved 97.7% fault classification accuracy with 0.8ms end-to-end latency, representing a 15.6x improvement over WiFi-6 (12.5ms) and 5.25x improvement over 5G (4.2ms) networks. The system demonstrated superior scalability with sub-linear processing time growth and maintained consistent performance across four bearing fault categories (normal, inner race, outer race, and ball faults) with macro-averaged F1-scores exceeding 97%.

With the rapid development of big data and edge computing, many researchers focus on improving the accuracy of bearing fault classification using deep learning models, and implementing the deep learning classification model on limited resource platforms such as STM32. To this end, this paper realizes the identification of bearing fault vibration signal based on convolutional neural network, the fault identification accuracy of the optimised model can reach 98.9%. In addition, this paper successfully applies the convolutional neural network model to STM32H743VI microcontroller, the running time of each diagnosis is 19ms. Finally, a complete real-time communication framework between the host computer and the STM32 is designed, which can perfectly complete the data transmission through the serial port and display the diagnosis results on the TFT-LCD screen.

Concept-based explanation methods, such as Concept Activation Vectors, are potent means to quantify how abstract or high-level characteristics of input data influence the predictions of complex deep neural networks. However, applying them to industrial prediction problems is challenging as it is not immediately clear how to define and access appropriate concepts for individual use cases and specific data types. In this work, we investigate how to leverage established concept-based explanation techniques in the context of bearing fault detection with deep neural networks trained on vibration signals. Since bearings are prevalent in almost every rotating equipment, ensuring the reliability of intransparent fault detection models is crucial to prevent costly repairs and downtimes of industrial machinery. Our evaluations demonstrate that explaining opaque models in terms of vibration concepts enables human-comprehensible and intuitive insights about their inner workings, but the underlying assumptions need to be carefully validated first.

We propose a bearing health management framework leveraging large language models (BearLLM), a novel multimodal model that unifies multiple bearing-related tasks by processing user prompts and vibration signals. Specifically, we introduce a prior knowledge-enhanced unified vibration signal representation to handle various working conditions across multiple datasets. This involves adaptively sampling the vibration signals based on the sampling rate of the sensor, incorporating the frequency domain to unify input dimensions, and using a fault-free reference signal as an auxiliary input. To extract features from vibration signals, we first train a fault classification network, then convert and align the extracted features into word embedding, and finally concatenate these with text embedding as input to an LLM. To evaluate the performance of the proposed method, we constructed the first large-scale multimodal bearing health management (MBHM) dataset, including paired vibration signals and textual descriptions. With our unified vibration signal representation, BearLLM using one set of pre-trained weights achieves state-of-the-art performance on nine publicly available fault diagnosis benchmarks, outperforming specific methods designed for individual datasets. We provide a dataset, our model, and code to inspire future research on building more capable industrial multimodal models (https://github.com/hatton613/BearLLM).

Predicting the remaining useful life (RUL) of ball bearings is an active area of research, where novel machine learning techniques are continuously being applied to predict degradation trends and anticipate failures before they occur. However, few studies have explicitly addressed the challenge of handling censored data, where information about a specific event (\eg mechanical failure) is incomplete or only partially observed. To address this issue, we introduce a novel and flexible method for early fault detection using Kullback-Leibler (KL) divergence and RUL estimation using survival analysis that naturally supports censored data. We demonstrate our approach in the XJTU-SY dataset using a 5-fold cross-validation strategy across three different operating conditions. When predicting the time to failure for bearings under the highest load (C1, 12.0 kN and 2100 RPM) with 25% random censoring, our approach achieves a mean absolute error (MAE) of 14.7 minutes (95% CI = 13.6-15.8) using a linear CoxPH model, and an MAE of 12.6 minutes (95% CI = 11.8-13.4) using a nonlinear Random Survival Forests model, compared to an MAE of 18.5 minutes (95% CI = 17.4-19.6) using a linear LASSO model that does not support censoring. Moreover, our approach achieves a mean cumulative relative accuracy (CRA) of 0.7586 over 5 bearings under the highest load, which improves over several state-of-the-art baselines. Our work highlights the importance of considering censored data as part of the model design when building predictive models for early fault detection and RUL estimation.

Diffusion models have demonstrated robust data generation capabilities in various research fields. In this paper, a Time Series Diffusion Method (TSDM) is proposed for vibration signal generation, leveraging the foundational principles of diffusion models. The TSDM uses an improved U-net architecture with attention block to effectively segment and extract features from one-dimensional time series data. It operates based on forward diffusion and reverse denoising processes for time-series generation. Experimental validation is conducted using single-frequency, multi-frequency datasets, and bearing fault datasets. The results show that TSDM can accurately generate the single-frequency and multi-frequency features in the time series and retain the basic frequency features for the diffusion generation results of the bearing fault series. Finally, TSDM is applied to the small sample fault diagnosis of three public bearing fault datasets, and the results show that the accuracy of small sample fault diagnosis of the three datasets is improved by 32.380%, 18.355% and 9.298% at most, respectively