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Expert Systems with Applications 37 (2010) 1419–1430

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Expert Systems with Applications


journal homepage: www.elsevier.com/locate/eswa

A multidimensional hybrid intelligent method for gear fault diagnosis


Yaguo Lei a, Ming J. Zuo a,*, Zhengjia He b, Yanyang Zi b
a
Department of Mechanical Engineering, University of Alberta, Edmonton, Alberta, Canada T6G2G8
b
State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an 710049, PR China

a r t i c l e i n f o a b s t r a c t

Keywords: Identifying gear damage categories, especially for early faults and combined faults, is a challenging task in
Feature extraction gear fault diagnosis. This paper proposes a new multidimensional hybrid intelligent diagnosis method to
Hybrid intelligent method identify different categories and levels of gear damage automatically. In this method, Hilbert transform,
Classifier combination wavelet packet transform (WPT) and empirical mode decomposition (EMD) are performed on gear vibra-
Gear fault diagnosis
tion signals to extract additional fault characteristic information. Then, multidimensional feature sets
including time-domain, frequency-domain and time–frequency-domain features are generated to reveal
gear health conditions. Multiple classifiers based on several classification algorithms and input features
are combined with genetic algorithm (GA). Because of the use of multidimensional features and the com-
bination of multiple classifiers, more accurate diagnosis results are expected with the proposed method.
Experiments with different gear damage categories and damage levels were conducted, and the vibration
signals were captured under different loads and motor speeds. The proposed method is applied to the col-
lected signals to identify the gear damage categories and damage levels. The diagnosis results show it can
reliably recognize single damage modes, combined damage modes, and damage levels.
Ó 2009 Elsevier Ltd. All rights reserved.

1. Introduction approaches are needed which allow relatively unskilled operators


to make reliable decisions without the need for a diagnosis special-
Gearboxes are one of the fundamental and most important ist to examine the gear vibration signals. Therefore, there is a de-
parts of rotating machinery employed in industries. Their function mand for techniques that can generate decision options on gear
is to transfer speed and power from one shaft to another. Their typ- conditions automatically and reliably.
ical applications include airplanes, automobiles, power turbines, Artificial intelligent techniques, such as artificial neural net-
and steel mills. If faults occur in critical gears of these machines works (ANN), fuzzy logic and genetic algorithms (GA), have been
during operation, serious consequences may occur. Therefore, fault successfully applied to automated detection and diagnosis of gears
diagnosis of gearboxes is crucial to prevent the mechanical system (Abumahfouz, 2005; Rafiee, Arvani, Harifi, & Sadeghi, 2007; Sa-
from malfunction that could cause damage or the entire system to manta, 2004). They increase the reliability of gear fault detection
halt, even personal casualties (Loutridis, 2008). Therefore, it is crit- and diagnosis systems. To overcome the limitations of individual
ical to detect and diagnose early faults that may develop in such classifiers based on artificial intelligent techniques and achieve
gearboxes. higher performance, the combination of multiple classifiers has
Different fault diagnosis methods have been developed and been intensively studied recently (Bi, Guan, & Bell, 2008; Hue-
used to detect and diagnose gear faults. One of the principal tools nupán, Yoma, & Molina, 2008; Rasheed, Stashuk, & Kamel, 2008).
for diagnosing gear faults is the vibration-based analysis because of Classifiers differing in classification algorithms or input feature
the ease of vibration measurements (Halima, Shoukat Choudhury, sets usually exhibit complementary classification behaviors. Thus,
Shah, & Zuo, 2008; Jafarizadeh, Hassannejad, Ettefagh, & Chitsaz, if the classification results of multiple classifiers, which employ
2008; Zuo, Lin, & Fan, 2005). Through the use of signal processing different classification algorithms or different input feature sets,
techniques, it is possible to obtain vital diagnostic information are combined by integration techniques to yield the final classifica-
from the vibration signals (Lei, He, & Zi, 2008; Lei, He, Zi, & Chen, tion result, the final performance is expected to be superior to the
2008; Loutridis, 2008). However, many techniques available today best performance of a single classifier (Fumera & Roli, 2005; Kittler,
require a good deal of expertise to apply them successfully. Simpler Hatef, Duin, & Matas, 1998). The weighted averaging technique is
the simplest and most widely used technique combining multiple
classifiers, which assigns a nonnegative weight to each individual
* Corresponding author. classifier. By optimizing an objective function, the classifier
E-mail address: ming.zuo@ualberta.ca (M.J. Zuo). weights can be estimated using various techniques.

0957-4174/$ - see front matter Ó 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.eswa.2009.06.060
1420 Y. Lei et al. / Expert Systems with Applications 37 (2010) 1419–1430

In this paper, a multidimensional hybrid intelligent diagnosis


method via multiple classifier combination and using different do- (2) Root mean square (RMS)
main feature sets is proposed to recognize early faults and com- vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
u n
bined faults occurring in gears. To obtain additional fault
u1 X 2
RMS ¼ t ðxi Þ ð2Þ
characteristic information, time- and frequency-domain features n i¼1
are extracted from the gear vibration signals and their frequency
spectra. Moreover, wavelet packet transform (WPT) and empirical
mode decomposition (EMD), two advanced time–frequency analy- (3) Kurtosis (KR)
sis techniques, are applied to decomposing the vibration signals. P
n ni¼1 ðxi  xÞ4
Then energy features are extracted from both the decomposed fre- KR ¼  2 ð3Þ
Pn
quency-band signals of WPT and the intrinsic mode functions 2
i¼1 ðxi  xÞ
(IMFs) of EMD. As a result, we have extracted multidimensional
features that include not only the time- and frequency-domain fea-
tures but also time–frequency-domain features from the vibration (4) Crest factor (CF)
signals. The multidimensional features extracted from the three max jxi j
domains can reflect the gear conditions from different perspec- CF ¼ qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Pn ffi ð4Þ
1 2
tives. They are then input into the classical classifiers based on n i¼1 ðxi Þ
multi-layer perceptron (MLP) neural network, radial basis function
(RBF) neural network, and K nearest neighbor (KNN) classification
algorithms. These three classification algorithms are created based (5) Shape factor (SF)
on different classification principles and therefore exhibit comple- qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Pn ffi
1 2
mentary classification performance. In order to improve the iden- n i¼1 ðxi Þ
SF ¼ 1 Pn ð5Þ
tification accuracy of gear damage in this paper, the nine i¼1 jxi j
n
classification results of these three classification algorithms using
the input features from the three different domains are combined Then, the following six additional time-domain features are
by genetic algorithm (GA) to come up with the final diagnosis extracted, which were specifically developed for gear damage
result. detection and reported in several NASA technical reports
In comparison with the fault diagnosis methods based on multi- (Decker, 2003; Decker & Lewicki, 2003) but seldom cited in
ple classifier combination reported in Zio, Baraldi, and Gola (2008) the published literature (Samuel & Pines, 2005). The applica-
Lei, He, Zi, and Hu (2007), the proposed method in this paper em- tion results to helicopter gearbox systems reported in the
ploys not only different feature sets as Zio et al. (2008) and Lei et al. NASA reports suggest that these features display different de-
(2007) did, but also complementary classification algorithms. Thus, grees of effectiveness in detecting gear damage. These features
it possesses a more powerful classification capability. are defined as follows (Decker, 2003; Decker & Lewicki, 2003;
Experiments on a gearbox test rig were carried out to verify the Samuel & Pines, 2005; Zuo, Li, & Fan, 2005).
effectiveness of the proposed multidimensional hybrid intelligent (6) FM0
diagnosis method. Gears with a chipped tooth, a missing tooth PP x
and several levels of crack were installed in the test rig and vibra- FM0 ¼ PH ð6Þ
h¼0 P h
tion signals were collected under various loads and motor speeds.
The diagnosis results validate that the proposed method is able to where PPx is the maximum peak-to-peak value of signal x, Ph is
recognize the gear damage categories as well as damage levels the amplitude of the hth harmonic of the meshing frequency,
effectively. and H is the total number of harmonics considered.

(7) FM4
2. Feature extraction P  4
n ni¼1 ðdi  dÞ
FM4 ¼  2 ð7Þ
2.1. Time-domain feature extraction Pn  2
i¼1 ðdi  dÞ

The time-domain signal collected from a gearbox usually where di is the ith measurement of the difference signal of the
changes when damage occurs in a gear. Both its amplitude and dis- signal xand d is the average of the difference signal. The shaft
tribution may be different from those of the time-domain signal of frequencies and their harmonics, the meshing frequencies and
a normal gear. Root mean square reflects the vibration amplitude their harmonics, and all first-order sidebands are defined to be
and energy in time domain. Standard deviation, kurtosis, crest fac- the regular meshing components. By removing the regular
tor and shape factor may be used to represent the time series dis- meshing components from signal x, the so called difference
tribution of the signal in the time domain. signal is generated. FM4 is actually the kurtosis of the differ-
First, five time-domain features, namely, standard deviation, ence signal. It is designed to complement FM0 by detecting
root mean square, kurtosis, crest factor and shape factor, are calcu- damage isolated to only a limited number of teeth and sup-
lated. They are defined as follows. posed to work well for detection of initial faults.
(1) Standard deviation (STD)
(8) NA4
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
u Pn
u 1 X n 1 4
i¼1 ðr i  r Þ
STD ¼ t ðxi  xÞ2 ð1Þ NA4 ¼  
n
2 ð8Þ
ðn  1Þ i¼1 1
PN 1
P n 2
N j¼1 n k¼1 ðr jk  r j Þ

where xi ði ¼ 1; . . . ; nÞ is ith sampling point of the signal x; n is where ri is the ith measurement of the residual signal of time
the number of points in the signal, and x is the average of the record xi and r is the average of r i , r jk is the kth measurement
signal. in the jth time record residual signal r j , rj is the average of r j ,
Y. Lei et al. / Expert Systems with Applications 37 (2010) 1419–1430 1421

and N is the number of time records in a run ensemble. The


complete data series collected is called a run ensemble. It is (2) Frequency center (FC)
further divided into N time records each including n data PK
points. The residual signal is generated by removing the regu- fk X k
FC ¼ Pk¼1
K
ð13Þ
lar meshing elements which include the shaft frequencies and k¼1 X k
their harmonics, and the meshing frequencies and their har-
where fk is the frequency value of the kth spectrum line and X k
monics. NA4 is created to overcome the shortcoming of FM4
is the kth measurement of the frequency spectrum.
that becomes less sensitive to the progression of fault in both
(3) Root mean square frequency (RMSF)
number and severity. For this reason, it is supposed to be able
to not only detect the onset of fault, as FM4 does, but also con-
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
uPK 2
u fk X k
tinue to react to the damage as it spreads and increases in RMSF ¼ t Pk¼1 K
ð14Þ
magnitude. k¼1 X k

(9) NB4
Pn (4) Standard deviation frequency (STDF)
1 4
i¼1 ðsi  sÞ
n
NB4 ¼   2 ð9Þ sP
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
1
PN 1 Pn 2
k¼1 ðsjk  sj Þ
K 2
N j¼1 n k¼1 ðfk  FCÞ X k
STDF ¼ PK ð15Þ
where sðtÞ is the envelope expressed as sðtÞ ¼ jbðtÞþ k¼1 X k

ifH½bðtÞgj; bðtÞ is the signal bandpass filtered about the meshing


frequency, H½bðtÞ is the Hilbert transform of bðtÞ, sjk is the kth MF indicates the vibration energy in the frequency domain. FC
measurement in the jth time record envelope sj ; sj is the average and RMSF show the position changes of the main frequencies. STDF
of sj , and N is the number of time records in a run ensemble. The describes the convergence degree of the spectrum power.
theory behind NB4 is that the damage on gear teeth will cause
transient load fluctuation that is different from that caused by 2.3. Time–frequency-domain feature extraction
normal teeth, and that this can be seen in the envelope of the
signal. In Sections 2.1 and 2.2, the time- and frequency-domain fea-
(10) Energy ratio (ER) tures are extracted from the vibration signals, respectively. In order
to acquire additional characteristic information of gear damage,
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
u1 Pn advanced signal processing techniques are used. Here, two ad-
u ðdi Þ2
ER ¼ tn1 Pi¼1 n 0 2
ð10Þ vanced signal processing techniques are employed to preprocess
n i¼1 ðdi Þ the vibration signals.
0 Wavelet transform (WT) possesses good local property in both
where di is the ith measurement of the difference signal, and di
time and frequency spaces (Peng & Chu, 2003). But the WT meth-
is the ith measurement of the regular meshing components,
od does not split the high frequency bands where the modulation
which include the shaft frequencies and their harmonics, the
information of machine fault exists. WPT furthers decomposition
meshing frequencies and their harmonics, and all first-order
of the high frequency bands and may generate a more precise fre-
sidebands. ER is defined as the ratio of the root mean squares
quency-band partition over the whole analyzed frequency bands.
between the difference signal and the signal containing only
Thus, the frequency resolution may be enhanced (Fan & Zuo,
regular meshing components.
2006).
(11) Energy operator (EOP) A vibration signal x is decomposed by WPT, and the decom-
P posed frequency-band signal bi;j is produced, where bi;j denotes
n ni¼1 ðrei  reÞ4 the jth frequency-band signal at level i ðj ¼ 1; 2; . . . ; J, where J is
EOP ¼  2 ð11Þ
Pn 2 the number of decomposed frequency-band signals and equals
i¼1 ðrei  reÞ
2I ; i ¼ 1; 2; . . . ; I, where I is the number of decomposition levels).
where rei equals x2i  xi1 xiþ1 and is the ith measurement of the The WPT decomposition process of x is shown in Fig. 1a. In this fig-
resulting signal re, and re is the average of the resulting signal. ure,fN is the upper limit of the frequency covered by x.
EOP is developed by first calculating the value x2i  xi1 xiþ1 for Empirical mode decomposition (EMD) (Huang, Shen, & Long,
every point xi ði ¼ 1; 2; . . . ; nÞ of the signal. The energy operator 1998) is able to decompose a signal into a set of complete and al-
is then computed by taking the kurtosis of the resulting signal. most orthogonal components named intrinsic mode functions
(IMFs). An IMF is a function that satisfies the following two condi-
tions: (1) in the whole data set, the number of extrema and the
2.2. Frequency-domain feature extraction number of zero-crossings must either equal or differ at most by
one, and (2) at any point, the mean value of the envelope defined
Four frequency-domain feature parameters are extracted from by local maxima and the envelope defined by the local minima is
the frequency spectrum of a gear vibration signal in this work. zero. IMFs represent simple oscillatory modes imbedded in the sig-
These frequency-domain parameters may contain information that nal. The EMD process of the signal x is depicted in Fig. 1b.
is not present in the time-domain feature parameters. They are de- At the end of the EMD decomposition we have a residue rL and a
fined as follows (Lei et al., 2007). collection of L IMFs cl ðl ¼ 1; 2; . . . ; LÞ. Summing up all IMFs and the
final residuer L , we obtain
(1) Mean frequency (MF)
X
L
x¼ cl þ rL : ð16Þ
1X K
MF ¼ Xk ð12Þ l¼1
K k¼1
Thus, we can achieve a decomposition of the original signal into L
where X k is the kth measurement of the frequency spectrum of IMFs and a residue r L . The IMFs c1 ; c2 ; . . . ; cL include different
signal x and Kis the total number of spectrum lines. frequency bands ranging from high to low. The frequency
1422 Y. Lei et al. / Expert Systems with Applications 37 (2010) 1419–1430

x (0–fN) x

b1,1 (0–fN/2) b1,2 (fN/2–fN) r1 c1

b2,1 b2,2 b2,3 b2,4


(0–fN/4) (fN/4–fN/2) (fN/2–3fN/4) (3fN/4–fN)
r2 c2

…… ……

bI ,1 bI , J rL c L
(0–fN/2I) ((2I-1)fN/2I–fN)
(a) (b)
Fig. 1. Signal decomposition: (a) WPT and (b) EMD.

components contained in each IMF are different and they change is in meshing or not. This change can be demonstrated by calculat-
with the variation of signal x, while r L represents the central ten- ing the energy entropies of the frequency-band signals of WPT and
dency of signal x. IMFs of EMD. It can also be illustrated by directly observing the en-
Making a comparison between WPT and EMD, we note that ergy distributions of the frequency-band signals of WPT and IMFs
WPT decomposes a signal into independent frequency bands with of EMD.
equal frequency widths and without overlap or gap such that they Fig. 2 shows the vibration waveforms of normal and damaged
do not have redundant or omitted information. However, WPT has gears, the decomposed frequency-band signals of WPT via db10,
the shortcoming that the analysis depends on the choice of the and the energy distributions when the decomposition level of
wavelet basis function. The number of frequency bands can be eas- WPT is 3. Fig. 3 shows the results when EMD is conducted. Because
ily controlled in WPT through setting the decomposition level. On the first six IMFs have captured almost all energy, other IMFs and
the other hand, EMD is based on the local characteristic time scales residual are omitted. From the energy distributions of WPT and
imbedded in the signal and may decompose the signal into a set of EMD, we can find that they are clearly different between the nor-
complete and almost orthogonal IMFs. During the decomposition, mal gear and the damaged one. Moreover, the energy entropies
there is no need for a basis function and both the number of IMFs calculated through Eq. (17) are shown in Table 1. It is seen that
and the actual scaling are determined by the signal itself. Thus, it is the entropy of the damaged gear is different from that of the nor-
a self-adaptive signal processing method. However, also because of mal one for both WPT and EMD. The energy entropy used here is
the self-adaptive characteristic of EMD, the number of IMFs can not defined as
be controlled beforehand. Thus, WPT and EMD process the signal
from different views and have their own characteristics including X
J
He ¼  pj log pj ð17Þ
advantages as well as shortcomings. This is the reason that we
j¼1
adopt both of them to preprocess the gear vibration signals in this
work. where pj ¼ Ej =E is the percentage of energy of the jth frequency-
While a gear with damage is running, the energy of the fault band signal of WPT or the jth IMF of EMD in the whole signal energy
P
vibration signal changes depending whether the damaged tooth E, where E ¼ Jj¼1 Ej .

0.2 0.2
Original

0 0
signal

-0.2 -0.2
0 1000 2000 3000 4000 0 1000 2000 3000 4000
0.2 0.2
Frequency-band

0 0
signals

-0.2 -0.2
0 512 1024 1536 2048 2560 3072 3584 4096 0 512 1024 1536 2048 2560 3072 3584 4096
1 1
Energy

0.5 0.5

0 0
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
(a ) (b )
Fig. 2. WPT decomposition results and energy distribution: (a) normal gear and (b) damaged gear.
Y. Lei et al. / Expert Systems with Applications 37 (2010) 1419–1430 1423

0.2 0.2

Original 0 0
signal
-0.2 -0.2
0 1000 2000 3000 4000 0 1000 2000 3000 4000

0.2 0.2
IMFs

0 0

-0.2 -0.2
0 0.4096 0.8192 1.2288 1.6384 2.048 2.4576 0 0.4096 0.8192 1.2288 1.6384 2.048 2.4576
4 4
1 x 10 1 x 10
Energy

0.5 0.5

0 0
1 2 3 4 5 6 1 2 3 4 5 6
(a ) (b )
Fig. 3. EMD decomposition results and energy distribution: (a) normal gear and (b) damaged gear.

The training of an MLP network involves finding values of the


Table 1
WPT and EMD energy entropies of the vibration signals of the normal and damaged connection weights, which minimize an error function between
gears. the actual network outputs and the corresponding target output
values in the training set. One of the widely used error functions
Method Normal gear Damaged gear
is the mean square error and the most commonly used training
WPT 1.70 1.74
algorithms are based on back-propagation.
EMD 1.06 1.30

3.2. RBF network

Based on the above analysis, we can see that the energy distri- The structure of an RBF network is similar to that of an MLP.
bution of either the frequency-band signals of WPT or the IMFs of But the activation function of the hidden layer is different from
EMD will change when the gear conditions change. Thus, the ener- that of the MLP and the Gaussian function defined below is used
gies of the frequency-band signals and the IMFs can be used as here:
additional time–frequency-domain features for gear damage
!
ðx  cÞ2
detection. According to the signal characteristics of the gear exper- f ðxÞ ¼ exp  2
ð19Þ
iments in this paper, db10 wavelet is used, the decomposition level 2b
of WPT is chosen to be 3, and the first six IMFs decomposed by where b and c are the width and center of the Gaussian function,
EMD are considered. Thus, 14 energy features are extracted here. respectively. The outputs of the hidden nodes give a measure
of the distance between the input features and the center c of
3. Brief review of the MLP neural network, the RBF neural the data cluster. The parameter b represents the radius of the
network, and the KNN classification algorithm hypersphere.
There are two steps in the training of the RBF network. First,
Artificial neural networks have been developed in the form of depending on the information contained in the input samples,
parallel distributed network models based on biological learning the nodes in the hidden layer and the center and the width of
process of the human brain. Among different types of ANNs, the Gaussian function are determined. In the second step, accord-
feed-forward multi-layer perceptron (MLP) neural network and ra- ing to the parameters in the hidden layer, input samples, and the
dial basis function (RBF) neural network are widely used by target values, the weights between the hidden and the output lay-
researchers (Haykin, 1999; Wasserman, 1995). ers are determined and adjusted by the principle of least squares
minimization.
3.1. MLP network
3.3. KNN algorithm
MLP network consists of an input layer of source nodes, one or
more hidden layers of computation nodes, and an output layer. The When D features are extracted from a sample with n data
commonly used structure of the MLP neural network consists of points, in the KNN classification algorithm, each training sample
three layers: input, hidden and output. The numbers of nodes in is represented in a D-dimensional space according to the value
the input and the output layers depend on the numbers of input of each of its D input features. The testing sample is then repre-
features and output classes, respectively. The number of hidden sented in the same space, and its K nearest neighbors are se-
nodes is determined using the geometric pyramid rule shown in lected. The class of each of these K neighbors is then tallied,
the following equation (Hansen, 1998; Yang, Stronach, & MacCon- and the class with the largest number of ‘‘votes” is selected as
nell, 2002). The sigmoid function is employed as the active func- the classification of the testing sample (Duda & Hart, 1973;
tion of the hidden nodes Hu, Yu, & Xie, 2008). The K nearest neighbors are usually deter-
pffiffiffiffiffiffiffi mined by computing the Euclidean distance between the testing
h¼ mn ð18Þ
sample and each of the training samples. The Euclidean distance
where h; m and n are the numbers of nodes in the hidden, input and between the testing sample TEd and the mth training sample
output layers, respectively. TRm;d is defined as:
1424 Y. Lei et al. / Expert Systems with Applications 37 (2010) 1419–1430

" #1=2
XD and time–frequency domains, respectively. Thus, combining MLP,
Dm ¼ ðTEd  TRm;d Þ2 ; RBF and KNN, and utilizing the input features extracted from the
d¼1 three different domains, a multidimensional hybrid intelligent
d ¼ 1; 2; . . . ; D; m ¼ 1; 2; . . . ; M ð20Þ diagnosis method is proposed to improve the identification accu-
racy of gear damage. The proposed method is shown in Fig. 4
where D and M are the numbers of input features and training sam-
and includes the following procedures. First, vibration signals
ples, respectively.
captured with accelerometers from gears are preprocessed with
Determining the neighborhood parameter K is a classical prob-
Hilbert transform, and the difference and residual signals are ob-
lem in the KNN classification algorithm. A commonly used rule of
tained. Then 11 time-domain features are extracted from the ori-
thumb is thatpthe ffiffiffiffiffi maximum value of the neighborhood parameter ginal, the difference, and the residual signals. Four frequency-
K is less than M (Ghosh, Chaudhuri, & Murthy, 2005; Pal, Bandyo-
domain features are extracted from the frequency spectra of
padhyay, & Murthy, 1998). Because the choice of the neighborhood
the vibration signals. Additionally, WPT and EMD are adopted
parameter is not
ffi the research focus of this
pffiffiffiffi pffiffiffiffistudy,
ffi the K value is se-
to decompose the vibration signals, and the energy feature is ex-
lected as b M c in this paper, where
pffiffiffiffiffi b M c indicates the largest
tracted from each of the frequency-band signals of WPT and the
integer less than or equal to M.
IMFs of EMD. By this point of time, the multidimensional fea-
tures have been extracted from all three domains. Second, with
4. The multidimensional hybrid intelligent diagnosis method the input features from each of the three domains, three differ-
ent classification algorithms, namely, MLP, RBF and KNN, are uti-
Multiple classifier combination is a collection of several classifi- lized to recognize the gear conditions. We refer the nine
ers whose individual decisions are combined in some way to clas- classifiers from top to bottom in Fig. 4 as classifiers 1–9. Finally,
sify testing examples. The idea of combining multiple classifiers in the weighted averaging technique with GA is employed to com-
a committee is based on the expectation that the committee can bine the outputs of the nine classifiers and come up with the fi-
outperform its members. The classifiers with different behaviors nal diagnosis result of gear conditions.
will provide complementary information to the integrator. When The final diagnosis result is given as follows:
they are combined, performance improvement is usually achieved.
8
Thus, diversity between the classifiers is recognized to be one of > P
9
> m ¼ 1; 2; . . . ; M0 ; c ¼ 1; 2; . . . ; 9
the desired characteristics required to achieve this improvement < ym ¼
> wc ym;c ;
c¼1
(Aksela & Laaksonen, 2006; Sirlantzis, Hoque, & Fairhurst, 2008; ð21Þ
>
> P
9
Zouari, Heutte, & Lecourtier, 2006). This diversity can be obtained >
: wc ¼ 1; wc P 0
c¼1
through using multidimensional feature sets and/or different clas-
sification principles. Therefore, if the classification results of multi- where ym and ym;c represent the classification results of the mth
ple classifiers using multidimensional feature sets and different testing sample using the hybrid intelligent method and the cth sin-
classification principles are fused by integration techniques, the fi- gle classifier respectively, wc is the weight associated with the cth
nal recognition accuracy is expected to be higher than that of any single classifier, and M 0 is the number of the testing samples.
of the participating classifiers. Of the various integration tech- In this work, the weights are estimated using GA to optimize a
niques proposed in the literature, the weighted combination fitness function. Real-coded genomes are adopted and a population
(weighted averaging technique) is the simplest and the most fre- size of 10 individuals is used starting with randomly generated
quently used, which is to assign a nonnegative weight to each indi- genomes. The maximum number of generations 100 is chosen as
vidual classifier. the termination criterion for the solution process. Non-uniform-
From the description in Section 3, it can be seen that MLP, mutation function and arithmetic crossover operator (Mich-
RBF and KNN have different classification principles and exhibit alewicz, 1999) are used with the mutation probability of 0.01
complementary classification performance. Additionally, the and the crossover probability of 0.8, respectively. The fitness func-
three different feature sets are extracted from time-, frequency- tion is defined as:

Hilbert MLP
Transform
11 time-domain
RBF
features
Difference and
residual signals KNN

MLP

Gears with Data 4 frequency-domain Diagnosis


FFT features RBF GA
accelerometers acquisition result

KNN

MLP
WPT
14 time-frequency-
domain features RBF
EMD
KNN

Fig. 4. Flow chart of the proposed method.


Y. Lei et al. / Expert Systems with Applications 37 (2010) 1419–1430 1425

8 1
> f ¼ 1þE
< tr
 M 12 ð22Þ
> P 2
: Etr ¼ M1 ðym  ym Þ ; m ¼ 1; 2; . . . ; M
m¼1

where Etr is the root mean square training errors, ym is the target of
the mth training sample, and M is the number of the training
samples.

5. Experimental setups and diagnosis results

In order to evaluate the effectiveness of the proposed method,


we conducted two experiments on a gearbox test rig. One is that
gears with a chipped tooth and a missing tooth were manufactured
and the gear vibration signals under normal condition, the two
damage conditions, and the combination of these two damage
Fig. 6. Gears with a chipped tooth and a missing tooth.
modes were captured. The other is that the cracks with different
levels were created at the tooth root of a gear. The data were used
to test the diagnosis performance of the proposed method to the 1200 to 2400 r/min with an increment of 300 r/min. Among the
early crack. three different loads, one was no torque generated by the brake
and the other two had different torques. The sampling frequency
5.1. Category identification of gear damage was 5120 Hz and the number of data points in each sample was
4096. Under an identical operating condition, four data samples
5.1.1. Experimental setup and data acquisition were collected. Therefore, 60 data samples were obtained for each
Fig. 5a shows the experimental system of the test rig used in gear condition and there were altogether 240 data samples for the
this paper and its system diagram is displayed in Fig. 5b. The sys- four gear conditions. Fig. 7 gives a vibration waveform collected
tem includes a gearbox, a 3-hp ac motor for driving the gearbox, under each of the four gear conditions.
and a magnetic brake for loading. The motor rotating speed is
controlled by a speed controller, which allows the tested gear 5.1.2. Diagnosis results
to operate under various speeds. The load is provided by the mag- As mentioned above, under the same gearbox operating condi-
netic brake connected to the output shaft and the torque can be tion (identical motor speed, load and fault mode), four data sam-
adjusted by a brake controller. As shown in Fig. 5b, the gearbox ples were collected. For each of the four gear conditions, 60
is driven by the motor and there are three shafts inside the gear- samples were acquired, and therefore the whole data set corre-
box, which are mounted to the gearbox housing by rolling ele- sponding to the four gear conditions includes altogether 240 sam-
ment bearings. Gear 1 (#1) on shaft 1 has 16 teeth and meshes ples. One hundred and twenty data samples were selected for
with gear 2 (#2) with 48 teeth. Gear 3 (#3) on shaft 2 has 40 training and the remaining 120 samples were used to test. This is
teeth and meshes with gear 4 (#4), which is on the output shaft a four-class classification task corresponding to the four different
(shaft 3) and has 24 teeth. Gears 10 (#10 ) and 40 (#40 ) are the gear conditions. The proposed multidimensional hybrid intelligent
tested gears. #10 is the same as #1 but it has a chipped tooth. diagnosis method is applied to identifying the categories of the
#40 is the same as #4 but it has a missing tooth. #10 and #40 gear damage. In order to know how well the proposed hybrid intel-
are shown in Fig. 6. ligent method based on multiple classifier combination works, we
The vibration was measured using accelerometers under each of also tested the performance of the nine individual classifiers. The
the following gear conditions: (a) all gears were normal, (b) #1 was identification accuracies of the proposed method and the individ-
replaced with #10 , (c) #4 was replaced with #40 , and (d) both #1 ual classifiers are shown in Fig. 8 and Table 2. We refer this exper-
and #4 were replaced by #10 and #40 , respectively. A DSP Siglab iment as Experiment #1 in Table 2.
analyzer 20-42 and a laptop with the data acquisition software Examining the results in Fig. 8 and Table 2, it can be seen that
were used to collect the vibration data. The speed of the driving the testing accuracy range of the nine individual classifiers is from
motor and the load of the magnetic brake were varied to simulate 71.67% to 88.33% and the average of these accuracies is 80.37%. But
the general operating conditions. The vibration data were acquired with the proposed method, the identification accuracy is enhanced
under three different loads and five different motor speeds from to 98.33%. The amount of improvement is quite large.

Gearbox
Motor
#1 #1’ Shaft 1 Brake controller
Siglab analyzer
Gearbox system
#2 Shaft 2 #3

Brake
Shaft 3 #4 #4’
Laptop
Speed controller

Accelerometers

(a) (b)
Fig. 5. (a) Experimental system and (b) diagram of the system.
1426 Y. Lei et al. / Expert Systems with Applications 37 (2010) 1419–1430

0.1
0 (a)
-0.1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
0.1

Amplitude (v)
0 (b)
-0.1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
0.1
0 (c)
-0.1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
0.1
0 (d)
-0.1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Time (s)
Fig. 7. Original waveforms of gears: (a) normal, (b) chipped tooth, (c) missing tooth, and (d) chipped tooth and missing tooth.

100
Testing accuracy %

90

80

70

60

50

The proposed
Classifier 1

Classifier 2

Classifier 3

Classifier 4

Classifier 5

Classifier 6

Classifier 8

Classifier 9
Classifier7

method

Fig. 8. Accuracy comparison of the nine individual classifiers and the proposed method for Experiment #1.

Table 2
Accuracy comparison between individual classifiers and the multidimensional hybrid intelligent method.

Experiment Data Classifier Classifier Classifier Classifier Classifier Classifier Classifier Classifier Classifier Average of the nine The proposed
set 1 2 3 4 5 6 7 8 9 classifiers method
#1 – 73.33 71.67 87.50 72.50 85.00 88.33 80.83 75.83 88.33 80.37 98.33
#2 A 95.56 100.00 100.00 92.22 100.00 100.00 96.67 100.00 100.00 98.27 100.00
B 83.33 84.72 90.28 61.11 81.94 87.50 86.11 76.39 83.33 81.63 100.00
C 61.67 60.00 75.00 85.00 68.33 55.00 61.67 80.00 50.00 66.30 98.33

5.2. Level identification of gear cracks gears with different crack levels are summarized in Table 3. Three
gears with different conditions (F0–F2) including one normal gear
5.2.1. Experimental setup and data acquisition and two faulty gears were tested in the experiment. For gear con-
In order to enhance the torque generated by the gearbox test dition F1, there was a very small crack at a tooth root and we de-
rig, a timing belt was added between the motor and the gearbox. fined it as an early crack. For condition F2, there was a bigger crack
In addition, the configuration of the gearbox system was modified at a tooth root but not serious, and therefore we defined it as a
and Fig. 9 is the modified system diagram. From the figure, it can developing crack.
be seen that the gearbox is driven by the motor through a timing These faulty gears are shown in Fig. 11.
belt. Gears 1–4 (#1–#4) have 48, 16, 24 and 40 teeth, respectively. The vibration was measured for each of the three gears using
Gear 3 is the tested gear. the same data acquisition system. The vibration data were ac-
For detecting and identifying an early crack, crack faults were quired under three different loads and five different motor speeds
simulated and the crack sizes of small proportions were created from 1200 to 2000 r/min with an increment of 200 r/min. Among
in the gearbox experiment. Let a be the crack angle, a one half of the three different loads, one was no torque generated by the brake
the chordal tooth thickness, and b the face width, which are shown and the other two had different torques. They were labeled as loads
in Fig. 10. Because the thinnest knife of the machine tools in our lab 0, 1 and 2, respectively. The sampling frequency was 5120 Hz and
is 0.4 mm, the crack thickness is 0.4 mm in the experiment. The the number of data points in each sample was 4096. Four data
Y. Lei et al. / Expert Systems with Applications 37 (2010) 1419–1430 1427

Gearbox
Timing belt
Speed controller #1 Shaft 1 Brake controller

#2 Shaft 2 #3
Motor
Brake
Shaft 3 #4

Fig. 9. Diagram of the modified system.


Fig. 11. Gears with different level cracks.

samples were collected under an identical operating condition and The testing results for the individual classifiers and the pro-
there are 180 data samples for these three levels of gear cracks. posed method are shown in Fig. 14 and Table 2, respectively. From
Fig. 12 shows sample vibration waveform of the normal and Fig. 14 and Table 2, we can see that the proposed multidimensional
cracked gears. The data collected here were labeled as Experiment hybrid intelligent method produces the highest classification cor-
#2 (shown in Table 2). rect rate, which is still 100%. However, the highest correct rate of
the nine individual classifiers is 90.28%. The accuracies of the nine
5.2.2. Diagnosis results individual classifies range from 61.11% to 90.28% and the average
We conducted three investigations on three different data sub- accuracy is 81.63%. Compared with the average accuracy, the pro-
sets (A–C) from the whole gear data collected from experiment #2 posed method increases the recognition accuracy by 18.37%.
as labeled in Table 2. The detailed descriptions of the three data Further, we performed another investigation on data set C. The
sets are shown in Table 4. For the first investigation on data set training and testing samples are described in Table 4. The data col-
A, the organization of the training and testing samples is similar lected under the gear with a developing crack (F2) were selected as
to that of Experiment #1 as described in Section 5.1.2. The acquired the training samples and the data of an early crack (F1) as the test-
180 data samples were divided into 90 training and 90 testing ing samples. The purpose of this investigation is to assess the gen-
instances. eralization ability of the proposed method to an early damage
The nine individual classifiers and the multidimensional hybrid when it is trained by developing damage samples.
intelligent method were used to recognize the three levels of the The multidimensional hybrid intelligent method and individual
gear cracks. Fig. 13 and Table 2 give their diagnosis results. Since classifiers are employed again and the corresponding identification
this classification problem is relatively simple, six individual clas- results are given in Fig. 15 and Table 2. It is observed from the re-
sifiers and the proposed method all achieve the highest possible sults that the identification accuracy (98.33%) achieved by the pro-
classification correct rate (100%). However, there are still three posed method is much higher than that of any individual classifier.
individual classifiers failing to produce the ideal identification For the individual classifiers, the accuracies ranged from 50.00% to
results. 85.00% with an average accuracy of 66.30%.
Another investigation was performed using data set B. In this
investigation, the training and testing samples are reorganized as
depicted in Table 4. The 108 training samples were collected under 6. Discussions
the lower motor speeds 1200, 1400 and 1600 r/min, while the 72
testing samples were collected under the higher motor speeds (1) In the above two experiments, Experiment #1 uses the data
1800 and 2000 r/min. The investigation for these training and test- collected from the normal gear, and damaged gears with a
ing samples is carried out to further clarify the robustness of the chipped tooth, a missing tooth and combination of a
proposed method with various motor speeds. chipped and a missing teeth, to train and test the proposed

Face width, b

Crack Crack angleα


Chordal tooth thickness, 2a

Fig. 10. Crack angle, face width and chordal tooth thickness of a gear.

Table 3
Geometry of the crack faults.

Crack fault mode Geometry of fault


Depth (mm) Width (mm) Thickness (mm) Crack angle
F0 0 0 0 –
F1 ð1=4Þa ð1=4Þb 0.4 45°
F2 ð1=2Þa ð1=2Þb 0.4 45°
1428 Y. Lei et al. / Expert Systems with Applications 37 (2010) 1419–1430

0.1
0
-0.1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
0.1
0

-0.1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
0.1
0

-0.1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Fig. 12. Original waveforms of gears: (a) F0, (b) F1, and (c) F2.

Table 4
Description of three data sets.

Data Number of training/testing Fault modes of training/ Motor speeds of training/testing samples Loads of training/testing Label of
set samples testing (r/min) samples classification
A 30/30 F0/F0 1200–2000/1200–2000 0, 1, 2/0, 1, 2 1
30/30 F1/F1 1200–2000/1200–2000 0, 1, 2/0, 1, 2 2
30/30 F2/F2 1200–2000/1200–2000 0, 1, 2/0, 1, 2 3
B 36/24 F0/F0 1200–1600/1800, 2000 0, 1, 2/0, 1, 2 1
36/24 F1/F1 1200–1600/1800, 2000 0, 1, 2/0, 1, 2 2
36/24 F2/F2 1200–1600/1800, 2000 0, 1, 2/0, 1, 2 3
C 30/30 F0/F0 1200–2000/1200–2000 0, 1, 2/0, 1, 2 1
30/30 F2/F1 1200–2000/1200–2000 0, 1, 2/0, 1, 2 2

100
Testing accuracy %

90

80

70

60

50
The proposed
Classifier 1

Classifier 2

Classifier 3

Classifier 4

Classifier 5

Classifier 6

Classifier 8

Classifier 9
Classifier7

method

Fig. 13. Accuracy comparison between the nine individual classifiers and the proposed method for data set A.

100
Testing accuracy %

90

80

70

60

50
The proposed
Classifier 1

Classifier 2

Classifier 3

Classifier 4

Classifier 5

Classifier 6

Classifier 8

Classifier 9
Classifier7

method

Fig. 14. Accuracy comparison between the nine individual classifiers and the proposed method for data set B.
Y. Lei et al. / Expert Systems with Applications 37 (2010) 1419–1430 1429

100

Testing accuracy %
80

60

40

The proposed
Classifier 1

Classifier 2

Classifier 3

Classifier 4

Classifier 5

Classifier 6

Classifier 8

Classifier 9
Classifier7

method
Fig. 15. Accuracy comparison between the nine individual classifiers and the proposed method for data set C.

multidimensional hybrid intelligent method. In Experiment (4) The problems studied in the two experiments cover single
#2, three investigations on three different data subsets were fault diagnosis (a chipped tooth and a missing tooth), com-
performed. The first investigation adopts the data of the nor- bined fault diagnosis (combination of chipped and missing
mal gear and the damaged gear with different crack levels to teeth), and early fault diagnosis (early crack). Additionally,
train and test the proposed method. The second investiga- the vibration data were collected under the various operat-
tion utilizes the data collected under the lower motor speeds ing loads and motor speeds. Thus, they are typical gear fault
of the normal and the damaged gears to train, and the data diagnosis cases. The satisfactory experiment results demon-
collected under the higher motor speeds to test the proposed strate the effectiveness and generalization ability of the pro-
method. The third investigation employs the data of a devel- posed method.
oping crack to train and the data of an early crack to test.
Analyzing the two experiment results, it is found that only 7. Conclusion
in the first investigation of Experiment #2, six of the nine
individual classifiers achieved the same high diagnosis accu- A new multidimensional hybrid intelligent method using differ-
racies as the proposed method since it is a simple classifica- ent domain features and multiple classifier combination is pro-
tion problem. For all other results, the proposed method posed for gear damage identification in this paper. In order to
obtains the best results in the gear fault diagnosis. It derive more fault information, Hilbert transform, wavelet packet
improves the classification accuracies by 17.96%, 18.37% transform, and empirical mode decomposition are performed on
and 32.03% respectively in comparison with the average gear vibration signals. Multidimensional features from the time,
accuracies of the individual classifiers. For the second inves- the frequency, and the time–frequency domains are extracted to
tigation of Experiment #2, the highest accuracy yielded by reflect the gear health conditions from different aspects. The clas-
the proposed method implies that it has better robustness sifiers based on multi-layer perceptron (MLP) neural network, ra-
under various motor speeds than the individual classifiers. dial basis function (RBF) neural network, and K nearest neighbor
In addition, the diagnosis results of the third investigation (KNN) classification algorithm are combined with GA to construct
of Experiment #2 demonstrate that the generalization abil- a reliable and accurate fault diagnosis method.
ity of the proposed method is superior to those of the indi- The gear experiments with different gear damage categories
vidual classifiers in gear early fault diagnosis. and levels were conducted on a lab gearbox. The data were col-
(2) All the above analysis results prove that the proposed multi- lected from the gears under different loads and motor speeds.
dimensional hybrid intelligent method obtains significant The analysis results on the gear data show that the proposed hy-
achievements in recognition accuracy and provides better brid intelligent method enables the detection of abnormalities in
generalization ability compared to the individual classifiers. gears and at the same time the identification of the categories
It can identify not only the different fault categories but also and levels of gear damage.
the different fault levels better. The success obtained by the
proposed method may be attributed to the following three Acknowledgement
points. (1) Preprocessing with Hilbert transform, WPT, and
EMD mines more fault characteristic information from the This research was supported by the Natural Sciences and Engi-
gear vibration signals. (2) Extracting multidimensional fea- neering Research Council of Canada (NSERC).
ture sets including time-domain, frequency-domain as well
as time–frequency-domain features better reflects the gear References
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