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3510710 IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 70, 2021
operations. Thus, CNN can be considered as an important The proposed novel convolutional neural network (NCNN)-
tool for the identification of defects in bearing and gear. based transfer learning methodology is as follows. First, broad
Guo et al. [15] introduced hierarchical adaptive CNN for sample training data from the source domain are feeded to the
pattern recognition and evaluation of fault size in bearing. improved CNN for learning of defect features. After successful
Azamfar et al. [16] carried out fusion of multisensor current learning, features learned by a few layers of NCNN are
data for carrying out diagnosis of gear box defects. When com- transferred for learning of fault knowledge from small training
pared with machine learning techniques based on hand-crafted samples. The learning from small samples is called fine-tuning
features, the authors proved the effectiveness of their pro- using data of the target machine. Thereafter, the knowledge
posed approach over conventional methods. Chen et al. [17] gained from NCNN is transferred to do fine-tuning of NCNN
applied CNN for identifying gear defects and established that from small training samples. The test data of target domain
CNN can provide better classification efficiency in comparison are then applied to fine-tuned NCNN for the purpose of
with SVM. identification of defects. The proposed cross-entropy function
CNN has very good recognition accuracy under persistent introduces sparsity in CNN and, hence, creates an effective
operating conditions. However, in real-world applications, deep learning which can work under a situation when training
machinery is operated under varying load and speed condi- data are not available in abundant.
tions. This reduces the performance of CNN more rapidly. The rest of the proposed work is arranged as follows.
This issue of CNN can be, however, resolved with the help of a Section II introduces the underlying theory and mathematical
new branch of deep learning names as transfer learning which concepts of CNN. Section III provides the proposed transfer
uses a knowledge-based technique to develop a model for little learning-based methodology for the identification of bear-
target which may or may not have the label [18]. In transfer ing faults. The experimental study and applicability of the
learning, the probability distribution functions for training and proposed methodology is provided in Section IV, whereas
testing samples are usually different. It is known as a domain Section V provides the concrete conclusions and future scope
adaptation branch and can be applied to various domains for of the present work.
achieving effective results [19]–[21]. Transfer learning is a
powerful deep leaning method in which preprocessing is not II. U NDERLYING T HEORY
necessary. It can be classified into various categories including A. Convolutional Neural Network
instance learning, feature transfer learning, parameter learn- The operation of various CNN layers can be mathematically
ing, and relational knowledge transfer learning [19]. Feature described [28]–[32] as follows.
transfer learning can represent the target domain into “good” Convolution Layer: The convolution operation for each
and encode the knowledge into a learned feature. Transfer layer of CNN can be mathematically expressed as follows [33]:
learning is gaining importance in various fields, such as image ⎡⎛ ⎞ ⎤
recognition, character recognition, emotion analysis, and so p+t
C H k=t,x=
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KUMAR et al.: NCNN FOR THE DIAGNOSIS OF BEARING DEFECTS IN ROTARY MACHINERY 3510710
The existing cost function is given as Fig. 2. Source and target domain machine. (a) Source domain. (b) Target
domain.
emodified = CE + β w2 . (5)
The fully connected layer has many parameters that adhere and
to deep learning from small data. In this work, a sparsity cost
N μ, μTj
is added in the existing cost function (5) which can make ⎡ ⎡ 2 2 ⎤ ⎤
the learning deep. The sparsity is incorporated by avoiding 8+ μ2 + μTj μ+μTj
⎢−6 tan 1+ 2+μ+μT tan⎣ 2 ⎦⎥
J ⎢ ⎥
unnecessary activation of neurons in the hidden layer of CNN j
⎢ 8 1+μ2 μTj ⎥
= ⎢ ⎡ ⎤ ⎥.
M
⎢
2 2 ⎥
emodiifed = CE + β w2 + β1 N μ, μTj j =1 ⎢ ⎥
(6) 8+ (1−μ) + 1−μTj
2
2−μ−μTj
⎣+ 4−μ−μTj tan⎣ 2 ⎦ ⎦
j =1
8 1+(1−μ)2 1−μTj
where (8)
m
CE = y Tj ln y Pj (7) P T
Here, y represents the predicted value, y represents the
j =1 target value, m is training data, the regularization factor (L 2 )
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3510710 IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 70, 2021
Fig. 3. Time-domain vibration data of source domain machine under different health conditions.
Fig. 4. Frequency-domain vibration data of source domain machine under different health conditions.
is denoted by β, β1 is the penalty of sparsity and j indicates Step 6: Obtain target domain data sets. Thereafter,
total neurons in hidden layer. fine-tuning of NCNN using the training data set of the target
machine is done by minimizing the modified cost function of
NCNN till appropriate performance is achieved.
III. M ETHODOLOGY
Step 7: Apply the test data of the target machine to fine-
The schematic flowchart of the proposed transfer learning- tuned NCNN for the identification of defects.
based fault diagnosis methodology is depicted in Fig. 1 and
works as follows.
IV. E XPERIMENT AND A PPLICATION OF
Step 1: Time-domain vibration data are acquired from the
P ROPOSED M ETHOD
source domain machine.
Step 2: Envelope spectrum of vibration data is computed. The efficiency of proposed scheme is validated on the
Step 3: Modification of existing cost function of CNN is bearing data set of two different domains, one is source
done to form NCNN. domain, and another is called target domain. The source
Step 4: Training of NCNN using training data (envelope machine [shown in Fig. 2(a)] consists of 0.5 HP motor (left),
spectrum) of the source domain. from which power is transmitted to the shaft using pulley
Step 5: Transfer of knowledge by transferring weight and arrangement. The motor shaft is supported by test bearings.
bias parameters of hidden layers. The layer whose parameters Single groove was introduced to the test bearings using
are transferred can be seen in Fig. 1. electro-discharge machining. The detail of defect conditions
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KUMAR et al.: NCNN FOR THE DIAGNOSIS OF BEARING DEFECTS IN ROTARY MACHINERY 3510710
Fig. 5. Time-domain vibration data of target domain machine under different health conditions.
Fig. 6. Frequency-domain vibration data of the target domain machine under different health conditions.
under study is given in Table I. For further detail of test rig, per second. The vibration signals obtained from source domain
please refer to articles [7], [34]. Vibration data were collected machine having defect conditions, mentioned in Table I, are
using an accelerometer, which was attached to the housing. shown in Fig. 3. For converting time-domain signals into
Vibration data were acquired at the rate of 70 000 samples frequency domain, envelope spectrums were computed and
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3510710 IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 70, 2021
TABLE I
D ETAIL OF S OURCE AND TARGET D OMAIN T RAINING AND T ESTING D ATA
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KUMAR et al.: NCNN FOR THE DIAGNOSIS OF BEARING DEFECTS IN ROTARY MACHINERY 3510710
TABLE II
C OMPARISON W ITH D IFFERENT M ETHODS
Fig. 10. Training performance achieved with target data. (a) Training
performance. (b) Cost function.
Fig. 11. Confusion matrix of the result achieved with target data (with
transfer learning).
target domain (360 samples, 30 samples of each condition) are Fig. 12. Confusion matrix of the result achieved with target data (without
transfer learning).
applied to fine-tuned NCNN. The defect identification results
of target domain data are presented in Fig. 11. The overall
accuracy of the proposed scheme is found to be 91%, which transfer learning. The confusion matrix of result obtained
is shown in Table II. without transfer learning is presented in Fig. 12. The defect
identification accuracy in case of inner race (5–8) and rolling
A. Comparison With Other Different Methods element defect (9–12) is very low. It is because of the
To prove the efficacy of the proposed transfer learning fact that defect on the moving components (inner race and
strategy, a comparison has also been made by applying dif- outer race) results in highly nonstationary signature. As a
ferent transfer strategies such as feature transfer learning, result, training with small data set of such defects results in
domain adaptation [36], and joint distribution learning [37]. under learning because network learns from scratch. On the
The defect identification results are presented in Table II. other hand, using transfer learning, the pregained knowledge
The modified cost function along with the sigmoid transfer attained over source domain data helps CNN in learning target
function gives defect identification accuracy of 91%. The domain defects conditions from small data set. A comparative
defect identification accuracy without transfer learning is very analysis of the results, presented in Table II, shows that the
less (highest accuracy achieved is 51% with Sigmoid + identification of defects through the proposed NCNN-based
modified cost function) in comparison with that achieved using transfer learning is much better than the existing CNN-based
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3510710 IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 70, 2021
tion, which can measure divergence between the desired ≥ 2 + μ + μTj tan 1. (A.5)
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KUMAR et al.: NCNN FOR THE DIAGNOSIS OF BEARING DEFECTS IN ROTARY MACHINERY 3510710
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3510710 IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 70, 2021
[34] R. Kumar and M. Singh, “Outer race defect width measurement Yuqing Zhou received the B.S. degree in comput-
in taper roller bearing using discrete wavelet transform of vibra- ing science from Jiangnan University, Wuxi, China,
tion signal,” Measurement, vol. 46, no. 1, pp. 537–545, Jan. 2013, in 2005, the M.S. degree from Southeast University,
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download-data-file He is currently an Associate Professor with the
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approach based on transfer learning from laboratory bearings to loco- ing, Wenzhou University, Wenzhou, China. He has
motive bearings,” Mech. Syst. Signal Process., vol. 122, pp. 692–706, authored more than 30 peer-reviewed international
May 2019, doi: 10.1016/j.ymssp.2018.12.051. journal papers. His current research interests include
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