Remaining Useful Life Prediction of Machining Tools by 1D-CNN LSTM Network
Remaining Useful Life Prediction of Machining Tools by 1D-CNN LSTM Network
Abstract—In the field of machining, machining tool life learning methods. Common statistics-based methods include
(degree of wear) is a key factor affecting the quality of the wiener processes [2], gamma processes [3], markov models [4],
machined workpiece. Over-protection strategies may increase etc. Common methods based on traditional machine learning
production costs and cause unnecessary machining tool downtime. mainly include support vector regression (SVR) [5], artificial
Therefore, if the remaining useful life (RUL) of the machining neural networks (ANN) [6], extreme learning machines (ELM)
tool can be accurately predicted, the work schedule will be and neuro-fuzzy system [7]. In fact, for a large amount of data
effectively optimized and the machining tool procurement cost in the actual machining process, traditional machine learning
will be reduced. In this paper, we propose a system schema that algorithms are sometimes difficult to extract hidden
integrates programmable logic controller (PLC) signals with
information that characterizes the degradation process of the
sensor signals for online RUL prediction of machining tools. The
preprocessed sensor signals are segmented and we propose
tool. In this respect, deep learning methods tend to have better
ensemble discrete wavelets transform (EDWT) to eliminate the effects, as it has powerful adaptive learning and anti-noise
noise of three-dimensional vibration signals and get time- ability, and it can automatically extract deep features, which is
frequency information. Then statistics features are extracted more versatile than traditional machine learning methods.
based on time domain and frequency domain analysis. Further, Common RUL prediction methods based on deep learning
we use spearman’s coefficient, autocorrelation and monotonicity include recurrent neural network (RNN) [8], Long Short-Term
indicators for feature selection to reduce feature dimensions. Memory network (LSTM) [9], convolutional neural networks
Finally, we use a 1D-CNN LSTM network architecture for (CNN) [10], and deep belief networks (DBN) [11], etc.
machining tools RUL prediction. The evaluation results show
that our system schema is feasible for the industrial field, and has
Among the commonly used deep learning models, CNN
a better performance than other common methods. has a very important position in the field of image recognition.
Due to its capacity to automatically extract features, it is also
Keywords—machining tools; remaining useful life; 1D-CNN; being used in the field of fault diagnosis and process
LSTM. monitoring today [13]. Liang [14] used the one-dimensional
convolutional neural network (1D-CNN) to extract the deep
I. INTRODUCTION features of high-speed train fault signal which can achieve the
The failure of machining tools may result in an increase in classification accuracy of 96.4%. Turker [10] also used 1D-
the surface roughness and a decrease in dimensional accuracy CNN on real motor data for real-time motor condition
of the workpiece, more seriously, the workpieces may be monitoring. And LSTM can effectively mine the hidden
scrapped or the computer numerical control (CNC) machine degradation trend in time series. Zheng [9] proposed an LSTM
may be damaged. Therefore, the remaining useful life (RUL) approach for RUL estimation. In fact, we can combine CNN's
of the machining tool is a practical problem to be solved in the high-dimensional feature extraction capacity and LSTM’s
factory. advantage on time series problems. After CNN extracts
features, we input them into the LSTM for training, then some
In recent years, studies on machining tools’ RUL prediction improvements in accuracy and speed can be achieved.
can be divided into two types: model-based methods and data-
driven methods. The model-based method mainly uses the Based on the working condition information and sensor
domain knowledge and physical principle model of the system data collected by the programmable logic controller (PLC) and
or component to perform calculations, and the failure behavior external sensors, this paper constructs the machining tool wear
of the machining tools can be quantitatively characterized. state evaluation and life prediction model to diagnose the wear
However, model-based methods are often difficult to achieve state of the machining tool. First, data preprocessing is
due to the uncertainty of model parameters and the complexity performed on the training dataset and the testing dataset,
of failure mechanisms of the machining tools in the cutting including denoising, outlier culling, and data structure
process [1]. In this case, data-driven methods are receiving defragmentation. The cleaned data is then decomposed by
more and more attention. ensemble discrete wavelets transform (EDWT) to obtain a
ቚσಿ ഥ തതത൯
ೕసభ൫௧ೕ ି௧ണ ൯൫௫ ൫௧ೕ ൯ି௫ ഢ ቚ
ܴ௦ ሺݔ ሻ ൌ మ మ
ටσಿ ഥ ಿ
ೕసభ൫௧ೕ ି௧ണ ൯ σೕసభ൫௫ ൫௧ೕ ൯ି௫
തതത൯
ഢ
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TABLE I. STATISTICS FRA TURES TABLE dimensional convolutional neural network (1D-CNN) is more
Feature Name Equation suitable than common convolution neural network. One of the
ே
MV ݔଵ ൌ ݕሺ݅ሻ Ȁܰ
ୀଵ
ே
VV ݔଶ ൌ ሺݕሺ݅ሻ െ ݔଵ ሻଶ Ȁܰ
ୀଵ
MDV ݔଷ ൌ ݉݁݀݅ܽ݊ሺݕሺ݅ሻሻ
ே
MSE ݔସ ൌ ඩሺݕሺ݅ሻ െ ݔଵ ሻȀܰ
ୀଵ
ே ଶ
ȁݕሺ݅ሻȁ
SMR ݔହ ൌ ൭ ൱
ܰ
ୀଵ
ே
ଶ
RMS ݔൌ ඩ൫ݕሺ݅ሻ൯ Ȁܰ
ୀଵ
MA ݔൌ ݉ܽݔȁݕሺ݅ሻȁ
ே
Energy ଼ݔൌ ݕሺ݅ሻଶ
ୀଵ
σே
ୀଵሺݕሺ݅ሻ െ ݔଵ ሻ
ସ
Kurtosis ଼ݔൌ
ሺܰ െ ͳሻߪ ସ
݈ ݈
III. 1D-CNN LSTM NETWORK FOR RUL ESTIMATION Where ݆ݔis the input from convolution layer, ߚ݆ is the
A. 1D-Convolutional and pooling ݈
weight matrix, ݀݊ݓሺȈሻ is the down sampling function, ݆ܿ is
The data collected during the actual machining of the tool
can be represented as a two-dimensional matrix with a time the baise. ݔఫ is the output of the ݆-th kernel in the ݈-th pooling
axis and a sensor variable axis. For time-series problems, one- layer.
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B. LSTM RNN, each unit of RNN is a simple chain structure, it
Long short term memory network (LSTM) [20] is a special processes the input sequence ቄݔଵ ǡ ݔଶ ǡ ǥ ǡ ܶݔቅ sequentially to
type of recurrent neural network (RNN) structure. In traditional
ܿ௧ ൌ ݂௧ ٖ ܿ௧ିଵ ݅௧ ٖ ݃௧
݄௧ ൌ ௧ ٖ ሺܿ௧ ሻ
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A. Data set description dimension. This article chooses to align them evenly. In
The dataset comes from the 2nd Industrial Big Data addition, some abnormal values exist in the original data. For
Innovation Competition organized by China Academy of example, the current contains abnormal maximum value and
Information and Communications Technology. According to abnormal minimum value (absolute value is even greater than
the PLC and external sensor in cyber-physical systems, the ͳͲଵ ), these values may affect the extraction of statistics. So
working condition information and sensor data during the this article discards the row containing the kind of outliers (this
machining process are collected to achieve the online article divides the outliers with the absolute value ͳͲଶ as the
monitoring and remaining useful life prediction of tool wear. limit).
PLC data is the complete processing history data, including
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feature matrix extracted by each tool is 600*k*n, where k is the should be 2.5 minutes. For the three tools in the training set,
number of .csv files, n is the number of extracted features. the complete life cycle is 240mins, 240mins, 180mins, even if
Since the data in each csv is fragment data of 1 minute
every 5 minutes, when the training set is subjected to RUL
labeling, as shown in “Fig. 10”, the 5 minutes expected value is
used as the label of the entire csv. For example, the RUL value
corresponding to the last csv file of each tool in the training set
Fig. 11. Results of the first machining tool in the test data set using different methods.
they have same remaining life of 100mins, their tool wear In the aspect of comparative experiments, we compares the
states are not consistent . Therefore, the concept of results of 1D-CNN, LSTM and 1D-CNN LSTM networks
remaining life ratio is introduced here. We normalize the after DWT transformation and 1D-CNN, LSTM and 1D-CNN
remaining useful life of each tool and renormalize it to LSTM networks after EDWT transformation. The model
obtain the true remaining useful life of the tool. parameters of CNN and LSTM are manually searched to get
better results. Since the scoring function is sensitive to
C. Results prediction results and the network output has some volatility,
The remaining life ratio of the machining tool’s begin and
end of the prediction can be obtained from the 1DCNN-LSTM
network. Then the remaining life of the test set can be
calculated by the following formula:
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in “Table III” as “MSE mean” and “Score mean”, etc. In the In the future, the proposed method can also add more
case of using score as the evaluation indicator, we can see that analysis of PLC signals. Thus, better results may be obtained
the 1D-CNN LSTM model using EDWT has the highest by analyzing the working conditions. At the same time, the
average score, and the standard deviation is very close to the practicality of the system can be improved by automatic
lowest value, indicating that EDWT can effectively improve parameter optimization.
the accuracy while ensuring the stability of the prediction.
ACKNOWLEDGMENT
When using mean square error as the evaluation indicator, the
1D-CNN LSTM model using EDWT completely defeated The authors would like to thank China Academy of
other methods. And regardless of which feature extraction information and Communications Technology, Foxconn,
method is used, the network structure using 1D-CNN LSTM CyberInsight for providing the raw data of CNC cutting tools.
has better performance than the 1D-CNN model or the LSTM Moreover, assistance provided by Dr. Zhao was greatly
appreciated.
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TABLE III. 20 TIMES TRAINING-TESTING RESULTS
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