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Measurement: Xiaoxun Zhu, Dongnan Hou, Pei Zhou, Zhonghe Han, Yiming Yuan, Weiwei Zhou, Qianqian Yin
Measurement: Xiaoxun Zhu, Dongnan Hou, Pei Zhou, Zhonghe Han, Yiming Yuan, Weiwei Zhou, Qianqian Yin
Measurement: Xiaoxun Zhu, Dongnan Hou, Pei Zhou, Zhonghe Han, Yiming Yuan, Weiwei Zhou, Qianqian Yin
Measurement
journal homepage: www.elsevier.com/locate/measurement
a r t i c l e i n f o a b s t r a c t
Article history: Vibration failure is a common problem in most rotating machinery, and vibration fault diagnosis is an
Received 6 January 2018 important means of ensuring stable equipment operation. The present work proposes a rotor vibration
Received in revised form 26 January 2019 fault diagnosis approach that transforms multiple vibration signals into symmetrized dot pattern (SDP)
Accepted 10 February 2019
images, and then identifies the SDP graphical feature characteristic of different vibration states using a
Available online 13 February 2019
convolutional neural network (CNN). SDP images reveal different vibration states in a simple and intu-
itive manner. In addition, a CNN can reliably and accurately identify vibration faults by extracting the fea-
Keywords:
ture information of SDP images adaptively through deep learning. The proposed approach is tested
Deep learning
Convolutional neural networks
experimentally using a rotor vibration test bed, and the results obtained are compared to those obtained
Symmetrized dot pattern with an equivalent CNN-based image recognition approach using orbit plot images. The rotor fault diag-
Fault diagnosis nosis precision is improved from 92% to 96.5%.
Rotor Ó 2019 Elsevier Ltd. All rights reserved.
https://doi.org/10.1016/j.measurement.2019.02.022
0263-2241/Ó 2019 Elsevier Ltd. All rights reserved.
X. Zhu et al. / Measurement 138 (2019) 526–535 527
cannot be guaranteed, and the diagnostic accuracy is affected. Fig. 1 illustration of r(i) as the polar radius, and h(i) and u(i) as
From the perspective of pattern recognition algorithms, the axis the two angles of the conventional polar space by which any point i
orbit, which reveals characteristic information regarding vibration in a time-series signal X = {x1, x2, . . ., xi, . . ., xn} is mapped onto a
faults in the form of plot images, and it is an important method for point S[r(i), h(i), u(i)] in polar coordinates in conjunction with a
visualizing the vibration signals of rotating machinery, has been plotting gain n (n h).
employed in conjunction with a deep learning algorithm to xi xmin
develop a rotating machinery fault diagnosis algorithm [14]. How- rðiÞ ¼ ð1Þ
xmax xmin
ever, the recognition rate of axis orbit plot images is substantially
reduced for low signal-to-noise ratio (SNR) signals. Moreover, the xiþq xmin
center offset and rotation of the orbit plot images introduce diffi- hðiÞ ¼ hs þ n ð2Þ
xmax xmin
culties for CNN identification. In an approach related to orbit plot
image recognition, the application of symmetrized dot pattern xiþq xmin
uðiÞ ¼ hs n ð3Þ
(SDP) images for the identification of vibration states [15] is a rel- xmax xmin
atively new approach that combines signal processing and image
In which, xmax and xmin are the greatest and the smallest values
analysis. SDPs are particularly useful because they represent differ-
in X ,hs is the sth rotation angle of a specified mirror symmetry
ent vibration states in a simple and intuitive manner. However,
plane, which is given as hs = 360 S/N, where s = 1, 2, . . ., n and n is
existing studies have adopted the conventional fault matching
the number of mirror symmetry planes, q is the time lag coeffi-
method for fault identification, which provides insufficient learn-
cient, and n is the gain of the plotting (n h). This signal represen-
ing depth with a correspondingly reduced diagnostic accuracy.
tation technique was first conceived for the visual characterization
The present work combines the advantages of SDP images and
of speech waveforms, and is particularly effective for low SNR
CNNs in image recognition and feature learning to develop a rotary
signals.
machine vibration fault diagnosis approach. Here, a vibration sig-
From the above analysis, we note that a SDP image derived from
nal is transformed into a SDP image, and the graphical features
a signal is n-mirrored in polar coordinates according to angle hs.
of SDP images characteristic of different vibration states are
This indicates that each mirrored image can represent the charac-
learned and identified through a CNN to realize vibration fault
teristics of the signal. In addition, a SDP diagram of N signals col-
diagnosis. The proposed approach is tested experimentally using
lected from different positions can also be displayed in the same
a rotor vibration test bed, and the results obtained are compared
polar coordinates to realize the fusion of information. Considering
to those obtained with an equivalent CNN-based image recognition
a periodic sinusoidal signal as an example ðyðtÞ ¼ sinð2 p 50ÞÞ,
approach using orbit plot images. The results demonstrate the
where the sampling frequency is 1 kHz, resulting in 1000 sampling
validity and significant contribution of the approach.
points, the SDP provides 6 mirrors in polar coordinates at 60° inter-
vals, as illustrated in Fig. 2.
2.1. Overview of SDP The distinct advantages of SDP signal representations are illus-
trated here using four simulated signals representative of different
Changes in the amplitude and frequency of time-series signals vibration states, including a simple periodic signal (Signal A),
can be depicted by means of an easy-to-understand visual repre- superimposed periodic signals (Signals B and C), and a complex
sentation by mapping a normalized time waveform into SDPs on superimposed periodic signal including a periodic impulse compo-
a polar graph to produce SDP images. For a time series signal X = nent (Signal D). The simulation signals are given as
{x1, x2, . . ., xi, . . ., xn}, any point i in X can be mapped onto a point
S[r(i), h(i), u(i)] in polar coordinates, where r(i) is the polar radius,
and h(i) and u(i) are the two angles of the conventional polar space,
as shown in Fig. 1. This mapping is conducted according to Eqs.
(1)–(3).
xðtÞ ¼ hðt Þ þ sðt Þ þ nðt Þ: ð4Þ ences in size or shape, although human experts can easily
discriminate between the shapes presented by SDP patterns
In which, h(t) represents aperiodic signal consisting of K = 4
robustly. As a result, SPD images remain manually monitored by
possible periodic components with amplitudes of Ai and frequen-
human operators in many industrial settings. Therefore, a machine
cies of fi, and is given as
learning method to autonomously identify different SDP patterns
X
K generated by rotor to establish a more robust and automatic vibra-
hðtÞ ¼ Ai sinð2 p f i tÞ; ð5Þ tion fault monitoring system are proposed.
i¼1
Table 1
Parameters of simulated time-series signals for illustrating SDP images.
Fig. 3. SDP images for different simulated signals based on Eqs. (4)–(6) and the parameters in Table 1.
l
xlj ¼ gðulj Þ ¼ gðblj downðxl1
i Þ þ bj Þ; ð8Þ (5) Output layer. In classification tasks, the feature vector
extracted from the CNN is classified and identified, and a
value representative of an identification probability is out-
where g() is the activation function in the S layer, blj is the
put for each class. The Softmax classifier was implemented
weight coefficient for the jth neuron at layer l, and down()
in this layer [20].
is the subsampling (or pooling) operation. Accordingly, new
features are obtained by pooling processes using commonly
The CNN uses the back propagation (BP) algorithm to imple-
employed pooling methods such as mean-pooling, max-
ment the training of network parameters [21]. The main parame-
pooling, and stochastic-pooling [18,19].
ters for the optimization of the CNN include the convolutional
kernel weight parameters k of the C layer, the weight coefficient
(4) Fully connected layer (FC layer). All neurons in the FC layer l
b of the S layer, the weight coefficient w of the FC layer, and the
are fully connected to the neurons of both layers l 1 and l
bias values b corresponding to each layer. Optimization of the net-
+ 1. The output of this layer can be given as
work parameters of each layer is conducted according to an objec-
tive function denoted as the sensitivity parameter, which is given
xlj ¼ r ulj ¼ r wlj xl1
l
þ bj ; ð9Þ as
j
1 X 2
where r() and wlj are the activation function and weight EP ¼ ypj opj ; ð10Þ
2 j
coefficient of the FC layer, respectively.
530 X. Zhu et al. / Measurement 138 (2019) 526–535
Fig. 4. SDP (above) and orbit plot (below) images for a single periodic signal with different signal-to-noise ratio (SNR) values.
where opj is the actual output and ypj is the ideal output of the j-th The SDP images with an image matrix of 128 * 128 was composed
layer. Here, the objective is to obtain an actual CNN output value by N signal fusion. Randomly selected part of the SDP image data
that approaches the ideal output. set as the training set of CNN. CNN can find more complicated
structures from complicated image and extract high-dimensional
3.2. Vibration state recognition method and more abstract representations and further, help computer to
establish complicated concept. Thus, the trained CNN model can
The method illustrated in Fig. 6 is proposed for identifying perform the classification of SDP image. To improve the recogni-
vibration states inherent in SDP images through the extraction tion accuracy of CNN in SDP image recognition, the remaining
and learning of SDP image features using the CNN. In the proposed SDP image data set is taken as the test set which is classified by
recognition method, we fuse the vibration data collected by m sen- using CNN model. By comparing the classification results, the effi-
sors at different positions as SDPs. All n signals are arranged in the ciency of the CNN model in the features extraction of SDP images
same polar coordinates according to a designated rotation angle. can be checked.
X. Zhu et al. / Measurement 138 (2019) 526–535 531
Fig. 6. Proposed vibration state recognition method based on SDP images and the CNN.
(c) Rubbing
Fig. 8. Representative waveforms obtained from the four sensors for the four different vibration states.
nected layer. In our experiments, considering the four kinds of fault adversely affected. The recognition results for the orbit plot images
classification with a less type classification than lenet5, The CNN are listed in Table 4. The experimental results for this method yield
network with one fully connected layer can achieve the same clas- an overall recognition accuracy of 93.8%, indicating that the pro-
sification accuracy, and also can effectively improve the computing posed recognition approach based on SDP images yields a higher
speed. On the other hand, in order to select the network, a compar- recognition accuracy than that based on orbit plot images.
ison between the lenet-5 and similar VGG network model are con- In order to compare the identification accuracy of CNN and
ducted and results show that, the accuracy rate of VGG model and methods in Ref. [15] in SDP image, the test set used in this paper
lenet5 model is basically in the same level (the accuracy of not was diagnosed using the failure matching based on the clustering
optimized VGG model is even lower than the classification results templates. First, all SDP images of the test set were converted into
of lenent5 model) and the optimal parameters were selected by image gray matrix, and 30 SDP images under each fault state were
trial and error method to identify SDP images. selected as the fault template. The characteristic value of the clus-
Some degree of noise of the signals derived from the experi- tering center is calculated by summing the image matrixes of all
mental station is observed. The recognition results for the pro- the templates of each running state of rotor and then calculate
posed method on the 400 test samples of all four vibration fault the average value. The threshold value was assigned as 0.75 with
states are listed in Table 3. The experimental results yield an over- is the same with that in Ref. [15]. The diagnosis of the remaining
all recognition accuracy of 96.5%, which represents high reliability. 280 SDP images was shown In Table 5 with an accuracy rate of
For comparison, orbit plot images were also constructed using 91.4%.
the data obtained from two of the perpendicularly placed sensors Keep 0.75 as constant, increasing the number of fault templates
(i.e., sensors #1 and #2) for the four vibration fault states, and as that in Ref. [15], taking 50 SDP images of each fault (50% of the
the results are shown in Fig. 10. From this comparison, it was test set) as the fault template for clustering analysis. The diagnosis
observed that each orbit plot image presents the vibration charac- of the remaining 200 SDP images was shown in the Table 6 with an
teristics obtained from only a single position. Meanwhile, a single accuracy rate of 92%.
SDP image can display the vibration characteristics of different SDP diagram shows some unique features, the method in Ref.
positions, which clearly demonstrates the advantages of SDP [15] can easily complete the fault recognition. However, if these
images in terms of information fusion. Then, the CNN was similarly fault templates do not appear, the method in Ref. [15] is difficult
applied for vibration fault recognition based on the obtained orbit to identify. Compared with method in Ref. [15], the features of
plot images. Orbit plot images require some preprocessing, such as weight sharing enable CNN to extract high-dimensional and more
centralization and reorientation, prior to conducting vibration fault abstract representation and further improve the recognition
state recognition [14]. Otherwise, the recognition accuracy will be accuracy.
X. Zhu et al. / Measurement 138 (2019) 526–535 533
Fig. 9. SDP images corresponding to the waveforms given in Fig. 6 for the different vibration states.
Table 2 5. Conclusion
The structure of the CNN in this paper.
Table 3
Confusion matrix obtained using the proposed method.
Classification result
Unbalanced Oil whirl Rubbing Misalignment
Ground truth Unbalanced 99 1 0 0
Oil whirl 1 98 1 0
Rubbing 1 0 94 5
Misalignment 0 1 4 95
534 X. Zhu et al. / Measurement 138 (2019) 526–535
Fig. 10. Orbit plot images corresponding to the waveforms of only sensors #1 and #2 given in Fig. 6 for the different vibration states.
Table 4
Confusion matrix obtained using orbit plot images for CNN based recognition.
Classification result
Unbalanced Oil whirl Rubbing Misalignment
Ground truth Unbalanced 96 2 1 1
Oil whirl 4 94 0 2
Rubbing 2 0 92 6
Misalignment 1 1 5 93
Table 5
Confusion matrix obtained using the Ref. [15] method (280 SDP images).
Classification result
Unbalanced Oil whirl Rubbing Misalignment
Ground truth Unbalanced 65 0 1 4
Oil whirl 1 62 6 1
Rubbing 1 1 66 2
Misalignment 3 2 2 63
Table 6
Confusion matrix obtained using the Ref. [15] method (200 SDP images).
Classification result
Unbalanced Oil whirl Rubbing Misalignment
Ground truth Unbalanced 46 1 0 3
Oil whirl 1 44 3 2
Rubbing 0 2 47 1
Misalignment 2 1 0 47
X. Zhu et al. / Measurement 138 (2019) 526–535 535
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