An Artificial Neural Network For Automated Fault Detection
An Artificial Neural Network For Automated Fault Detection
An Artificial Neural Network For Automated Fault Detection
Abstract
Intelligent and interconnected cyber physical systems are Predictive maintenance aims to ensure the maximum
a key enabler for future cost-efficient, automated and deployment efficiency o f production systems and thereby
flexible industrial production systems. Predictive save high costs of unnecessary maintenance or in the
maintenance and condition monitoring are important opposite case, costs associated with breakdowns
techniques in order to reduce costs associated with However, automated fault detection is a challenging task,
unnecessary maintenance or premature breakdowns. In as the system can react to different faults in different
this paper, we propose techniques from supervised ways. Fault detection means the tracking o f unexpected
learning for automated malfunctioning detection. For that behavior o f relevant parameters and the discovery of
purpose, we train an artificial neural network on time patterns in data that might indicate malfunctioning.
series data representing the internal system behavior. We Machine learning techniques are a common “working
present experimental results from an industrial motor horse” for the task o f pattern recognition. Several
control system. We use a digital twin o f the electronic machine learning algorithms have been used for the task
component that models the relevant features o f the o f predictive maintenance [2, 3].
physical system. The obtained information can be used
during the runtime o f technical systems and installations
for a criticality analysis and the subsequent selection of
measures.
1. Introduction
The prevalence o f software-controlled functionalities in
industrial systems is continuously increasing. The high
degree o f connections between system parts leads to a
strong interconnection o f the system. This means that in
the worst case scenario, small faults o f system parts can
propagate to cause failures o f the entire system.
Condition monitoring as part o f predictive maintenance Fig. 1: Schematic of the proposed automated fault
serves to determine the condition o f the overall system, detection pipeline
system parts or components to notice subtle changes in
relevant parameters in order to predict when maintenance
or other measures should be performed to prevent Virtual prototyping (VP) has gained popularity as it
failures. [1]. allows for a validation o f a new design during the
development stage prior to building a physical prototype
[4, 5]. In addition, VP is also used for maintenance
Proceedings of the 6th All-Russian Scientific purposes [6]. In this scenario, possible faults or
Conference "Information Technologies for Intelligent degradation effects are simulated virtually to predict
Decision M aking Support", M ay 28-31, Ufa - when maintenance should be provided to the physical
Stavropol, Russia, 2018 system.
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In this paper, we present a supervised machine learning and a very deep residual network and argue that with
algorithm for the task o f automated fault detection. A deep learning, heavy pre-processing or feature crafting is
schematic o f the simulation and the automated fault no longer necessary to achieve premium performance.
detection pipeline is presented in Fig.1. The general idea They demonstrate their findings on the UCR data set.
is to train an artificial neural network (ANN) with labeled
Several authors have applied methods o f time series
data that is obtained from a virtual system modeled
classification for the task o f condition monitoring and
according to a physical system and therefore being its
automated fault detection. Zhong et al. studied fault
digital twin. For the task o f condition monitoring,
diagnosis for a gearbox based on Support Vector
different labels indicate different system states. Some
Machines for condition monitoring [10]. The data was
system states contain faults and thus, the ANN learns to
obtained from an experimental test rig. Relevant features
recognize when faults are present. After the training
were extracted from the vibration signals o f the gearbox
stage, the ANN can accept data from the physical system
with the wavelet packet transform as well as using time-
in order to track potentially dangerous faults. Our main
statistical features. For an optimal set of features, the
conclusion is that the ANN is very successful in
authors reported an accuracy o f 100% on the test set.
separating faulty from faultless cases, since we achieve
Shulian et al. presented an artificial neural network as a
an accuracy o f 100% on the validation set after only
classifier for the task o f fault diagnosis o f a gearbox [11].
training for 4 epochs.
The data was obtained from a physical gearbox and faults
The main contributions o f this paper are: were classified according to their severity such as e.g.
‘gentle fault’ or ‘bad fault’. Aydin et al. presented a
• We demonstrate a methodology to generate an
fuzzy c-means algorithm that was used to distinguish
automated condition monitoring system from
between broken rotor bar faults and the healthy condition
VP.
o f an induction motor at four different operation speeds
• We show that techniques from supervised [12]. Recently, Yang et al. showed a time-efficient
machine learning serve as a valid method to clustering-k-nearest-neighbors algorithm for the purpose
distinguish between faulty and faultless cases o f fault detection in gas sensor arrays [13]. The authors
and thus are suitable for the task o f fault verified the performance o f the algorithm with a real gas
detection. sensor array experimental system with different kinds o f
faults. Campbell et al. examined the suitability o f
• We illustrate our methodology using an artificial neural networks to be used for condition
industry-relevant use-case. monitoring o f electric power transformers [14]. Sreejith
The remainder o f the paper is structured as follows: In et al. demonstrated an algorithm for the task o f fault
Section 2, we discuss previous publications on the diagnosis o f rolling element bearings using time-domain
classification o f time series data and the use o f supervised features and feedforward neural networks [15]. After the
machine learning algorithms for condition monitoring. In training stage, an accuracy o f 100% to distinguish
Section 3, we present our analysis approach for the different states o f the bearing was reported.
employed methodology and time series classification. In The references mentioned above were all evaluated with
Section 4, we describe our industrial use-case in more data obtained from physical experimental setups and
detail. Experimental results are provided in Section 5 and made no use of VP. In general, most evaluations were
finally, the paper ends with a conclusion in Section 6 . performed on measured data. Li et al. used both VP as
References are provided in Section 7. well as experimental studies for the task o f gear multi
fault diagnosis [16]. The employed methods include the
wavelet transform technique, Autoregressive models and
2. Related Work Principal Component Analysis. With our work, we
The data that is used for the fault detection algorithm has complement the existing research for automated fault
the nature o f time series. For the tasks o f condition detection in industrial systems.
monitoring and fault detection, time series classification
has risen in popularity in the last decade. Time series
analysis is a well-studied field [7]. In particular, time 3. Analysis Approach
series classification has been studied extensively. Bagnall
et al. presented a comprehensive review o f different 3.1. Methodology
classification algorithms and their evaluation on publicly The automated fault detection framework was briefly
available data sets from the University o f California introduced in the Introduction and Fig. 1 and is explained
Riverside time series classification archive (UCR) [8]. here in more detail. An extended schematic o f the
They have found that 1-NN DTW and Rotation Forest automated fault detection pipeline is displayed in Fig. 2.
classifiers offer the best results in most cases. Despite
these findings, we have used a shallow ANN as a We differentiate between the Virtual Domain, the
classifier, because it was very successful for our use-case. Analysis Domain and the Physical Domain. The Virtual
In a recent publication, Wang et al. showed that deep Domain contains the virtual prototype and data obtained
learning can be used for time series classification [9]. The from it, while the Physical Domain contains the physical
authors implement both a fully convolutional network counterpart that is modelled by the VP. Data output from
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both the Virtual and the Physical Domains is analyzed in evaluation o f time series data produced by the physical
the Analysis Domain. The arrows indicate the directions system. Analogously to the different classes in the Virtual
o f information flow between the various stages within the Domain, a criticality analysis can be performed for the
whole system. The domains and their interconnections system state o f the physical system. Based on the results
will be explained in the following, starting with the o f the criticality analysis, the subsequent decision making
Virtual Domain (left part o f Fig.2). and safety measure stages are analogous to the Virtual
Domain as described above.
The System under Test (SuT) and test bench
configurations are defined for the stimulation o f the VP The employment o f VP for the simulation o f different
within the test bench. Upon stimulation, the VP produces faults has several benefits. First, running a simulation is
time series as output. Depending on the parameters usually much faster than tracking the faults physically
defined in the SuT and test bench configurations, the and for example, in case o f degradation effects, gaining a
resulting time series have different shapes. In half o f the sufficient amount o f data in the physical world can take
cases, a fault is injected during the simulation. The time very long. Additionally, with the employment o f VP, it is
series are then used as training data to train an artificial
neural network (ANN) in the Analysis Domain. The def p a a ( t s , n ) :
ANN learns patterns in the time series and determines f = n p .z e ro s ( n ) # in itia liz e s
class labels to group similar time series into the same d = le n ( t s ) / / n # slic e length
classes. The classes can either represent different motor fo r i in ra n g e ( 0 , n ) :
4. Use-Case
The use-case for the proposed time series classification
approach is a motor control model. This model is
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That means that from 500 time series used for training,
100 contain faults and 400 do not contain faults.
To reduce the samples’ dimension of to a
more manageable number, we define and extract a
desired
5. Experimental Results
The full data set consists o f 8000 time series similar to
those displayed in Fig.5 and Fig.6. The motor parameters
that are modified to get this number are:
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shallow ANN can learn meaningful patterns from
features extracted with PAA and distinguish between
faulty and faultless time series.
It is important to discuss the limitations o f our approach.
We considered the task o f automated fault detection in
the context o f supervised learning. The disadvantage of
this approach is that we have to rely on the availability of
labeled data. As a next step, it would be interesting to
tackle the automated fault detection problem with
techniques from unsupervised learning. This way, a
solution for cases when there is no labeled data could be
offered.
Fig. 9: Validation accuracy during the first training
epochs of the ANN
6. Conclusion
We have demonstrated a methodology supporting
prototype is a digital twin of a physical system, the
automated fault detection using virtual prototyping. We
trained network can be applied for condition monitoring
have shown that methods from supervised machine
o f the physical machine.
learning are suitable for the task o f automated fault
detection. Based on the results from the automated fault
detection, a criticality analysis can be performed to judge
which measures must be triggered. We have evaluated 8. Acknowledgements
our methods on data obtained from VP and, since the This work has partially been supported by the German
virtual Ministry o f Science and Education (BMBF) in the project
SAFE4I under grant 01IS17032C.
9. References
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Fig. 8: Training loss for the training of the ANN
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