CONDITION MONITORING AND FAILURE ANALYSIS OF AUTOMOBILE COMPONENTS USING DEEP LEARNING

Indian Institute of Technology (BHU), Varanasi

B.Tech. Project Final Report

Made By:-
1. Divyansh Garg (17135032)
2. Harshad Kumbhare (17135038)
3. Harsheet Jain (17135039)
4. Harsh Vardhan Singh (17135110)
5. Harihar Patel (17134004)

Supervised By:-
Dr. R.R. Sahoo
Co-supervised By:-
Dr. Cherian Samuel

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 CONDITION MONITORING AND FAILURE ANALYSIS OF AUTOMOBILE COMPONENTS USING DEEP LEARNING

​CONDITION MONITORING AND FAILURE ANALYSIS OF

AUTOMOBILE COMPONENTS USING DEEP LEARNING

1. EXTERNAL AUTOMOBILE COMPONENTS DAMAGE DETECTION /

CLASSIFICATION USING DEEP LEARNING. ​(Done In 6th Sem)

2. INTERNAL AUTOMOBILE COMPONENTS CONDITION MONITORING / FAILURE

ANALYSIS USING DEEP LEARNING

1. ABSTRACT:

Computer vision can be used for car damage classification/detection.For proper and
efficient functioning of a car each component has to work efficiently and in tandem with
each other.
In order to achieve this extensive collection of data and efficient use of it is necessary.
In this project we are selecting gearboxes for monitoring. Efficient gearbox health
monitoring and effective representation of diagnostic results of dynamical systems have
remained challenging. In this project, a new approach to using deep learning for
translating diagnostic results of one-dimensional time series analysis into graphical
images for fault type and severity illustration is presented. Next, a Convolutional Neural
Network (CNN) learns the underlying features in the time frequency domain from these
images and performs fault classification.Experiments on gearbox data demonstrates
effectiveness and efficiency of the developed approach with a classification accuracy
better than 86%.

2. INTRODUCTION:

The widespread application of gearboxes in manufacturing and transportation has

continually motivated research that aims at effective and efficient gearbox health
monitoring and fault
diagnosis techniques. A majority of the techniques reported in the literature utilize
vibration signals acquired by sensors for fault analysis. The most important components
in gearbox
vibration spectra are the tooth meshing frequency and its harmonics, together with
sidebands caused by modulation phenomena. Increments in the number and amplitude
of such sidebands may indicate a fault occurrence and deterioration. Traditional
methods to obtain vibration spectra are Fast Fourier Transforms (FFT) and Short-Time

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 CONDITION MONITORING AND FAILURE ANALYSIS OF AUTOMOBILE COMPONENTS USING DEEP LEARNING

Fourier Transforms (STFT). It has been shown that FFT is unable to reveal the dynamic
features of non-stationary signals, while STFT cannot achieve satisfactory resolution in
both the time and frequency domains at the same time. In recent years, it has been
demonstrated that time-frequency distribution of the wavelet transform is more effective
in identifying frequency transitions along time than the traditional approaches, owing to
its multi-resolution feature localization capabilities. There has been ongoing research
towards using neural networks in combination with wavelet transforms to achieve good
classification accuracy. Use of neural networks for fault classification has been
demonstrated previously in the case of helicopter gearbox .However, multisensor
installation was required to achieve class separability in fault classification and the
accuracy was dependent on feature selection. In this paper, an automatic approach for
feature identification based on deep learning is established. Deep neural architecture
has been used in numerous classification applications such as image recognition, object
classification and handwritten digit data classification . Deep neural networks have also
been used in health diagnosis such as in the case of electric power transformers and
aircraft engines and electro motors.

3. DATASET DESCRIPTION:

The dataset is collected from ​OpenEI​.Gearbox Fault Diagnosis Data set include
the vibration dataset recorded by using Spectra Quests Gearbox Fault
Diagnostics emulator. Dataset has been recorded with the help of 4 vibration
sensors placed in four different directions. Data set has been recorded under
variation of load from ’0’ to ’90’ percent. Data set has been recorded in three
different scenarios:
1. Healthy condition
2. Broken Tooth Condition
3. Worn teeth.

● Image Processing
For each severity level, two 30 s long vibration data series are collected at
8192 Hz sampling rate. Every 0.5 s data series, namely 4096 data points,
is converted to one time-frequency spectra image. Distinguishing
becomes more difficult after converting these images to grey images,
which are taken as inputs to DCNN.

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 CONDITION MONITORING AND FAILURE ANALYSIS OF AUTOMOBILE COMPONENTS USING DEEP LEARNING

4. DEEP CONVOLUTIONAL NEURAL NETWORK:

1.​ Diagnosis methods

A deep learning analysis is proposed for condition monitoring of gearbox faults.

In this section, fundamental theory of Deep CNN is first introduced, followed by
the illustration of automated fault severity classification based on time-frequency
images through integrated wavelet and DCNN.

2. Deep Convolutional Neural Network

Deep neural network (DNN) is a type of artificial neural network with multiple
hidden layers of units embedded between the input and output layers, and it has
been gaining popularity in recent years, particularly in the field of image
processing and classification. Images contain features that reflect the underlying
architecture that makes each image a unique representation. These features

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CONDITION MONITORING AND FAILURE ANALYSIS OF AUTOMOBILE COMPONENTS USING DEEP LEARNING

might not appear to be visually distinct between images. However, deep neural
networks can be trained to learn such features at different levels of abstraction.
Deep Convolutional neural network (DCNN) is one of the DNN structures. It
consists of hierarchically arranged trainable stages that learn the efficient internal
representation for all data .The neurons in a DCNN are arranged in the form of
feature maps. In the case of image processing, the input to the network is a 2D
array representing the image. A typical convolutional network consists of two to
four stages of convolutional layers and pooling layers. The input to a
convolutional layer is an image x of size m*n. The convolutional layer contains k
kernels (filters) of size p*q, smaller in dimension than the input image. The output
of the convolutional layer is a set of k feature maps of size (m*p + 1) (n*q + 1) by
striding over one pixel i.e. (stride=1).

3. DCNN based diagnosis

Excellent results have been demonstrated in optical defect detection using

DCNN. It has been shown that convolutional networks can achieve an error rate
of 7 percent at image analysis compared to manual visual inspection method in
steel defect classification. Hence, using the advantages of deep learning, we
propose a health condition monitoring system. Gearbox vibration signals can be
converted to images These images corresponding to different fault types may be
different, as the characteristic frequencies of faults are different. But it is hard to
differentiate these images through visual inspection if they belong to the same

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 CONDITION MONITORING AND FAILURE ANALYSIS OF AUTOMOBILE COMPONENTS USING DEEP LEARNING

fault type but different fault severity levels, as the differences of sidebands
amplitudes can be easily buried by surrounding frequency components (e.g.
meshing frequency components) with larger amplitude. DCNN is therefore
applied to dig the evolution of sidebands amplitudes, based on investigating the
brightness of specific pixels corresponding to sidebands. Its architecture is
attuned to learn the underlying features of images and classify them. By training
these images for different fault categories, the network parameters are fixed.
Oncoming vibrations signals can be classified by DCNN, forming an effective
health condition monitoring system.

5. EXPERIMENTAL SETUP:

The provided datasets are related to radial vibration signals acquired in a

gearbox setup with three different gear conditions: healthy, one chipped tooth,
and three worn teeth in helical gears.

SCHEMATIC REPRESENTATION OF SETUP

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 CONDITION MONITORING AND FAILURE ANALYSIS OF AUTOMOBILE COMPONENTS USING DEEP LEARNING

6. NETWORK SETUP AND TRAINING:

2D images are used as inputs to the DCNN. The first layer following the input
layer is a convolutional layer with 6 feature maps of kernel size 11 11. This is
followed by a mean-pooling layer of size 2 2. The next layer is a convolutional
layer with 12feature maps of 6 6, followed by a 2 2 mean-pooling layer. The
output layer contains 4 neurons
corresponding to the 4 different fault states. All the layers are fully connected.
Sigmoidal function is used as the activation function. Stochastic gradient descent
method was used to train the network with a learning rate of 1. The batch size
was taken as 5. The training was carried out for 50 epochs. The time taken to
train the network was 4.25 s and for classifying the test data was around 0.001 s.

7. IMPLEMENTATION OF MODEL:

At first, we tried to classify the datasets into two classes using logistic regression.
The classification classes include healthy and faulty gear.The traditional logistic
regression model gave an overall accuracy of 68 percent. Then we used CNN for
better accuracy. We converted the vibrational data into images and then fed
them into the CNN architecture. The model used the input images and classifies
the dataset into three classes that include no fault class, chipped tooth class and
worn teeth class. The accuracy from this model was 84 Percent.

8. RESULT & CONCLUSIONS:

In the previous paper, we proposed a deep learning-based solution for external

car damage classification and in this paper we propose internal component
condition monitoring/failure analysis. We experimented with DCNN such as
training CNNs from random initialization, Convolution Autoencoder based
pre-training followed by supervised fine tuning and transfer learning. We
observed that the transfer learning performed the best. We also note that only
car specific features may not be effective for damage classification. It thus

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CONDITION MONITORING AND FAILURE ANALYSIS OF AUTOMOBILE COMPONENTS USING DEEP LEARNING

underlines the superiority of feature representation learned from the large training
set. Up until now we were able to detect external damages by training CNN’s.
We were able to detect (bumper dent, door dent, glass shatter, broken
headlamp, broken tail lamp, scratch, and smash) with an accuracy of 70.55%.

The classification rate is calculated as the ratio of the number of correctly

classified test samples to the total number of test samples. The network
performed with an average classification accuracy of 68 percent , which was
achieved by our Logistics Regression model. For Implementation of our Model,
We use CNN Model. The C ​ NN model produces an accuracy of 84 percent. The
model shows CNN being able to learn the sequence and produce encodings and
thus producing a better result.

Model Name Accuracy

Logistic Regression 68%

CNN 84%

Model Accuracy Bar Plot

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9. ​REFERENCES:

i. ​https://easychair.org/publications/preprint/RlQ2
ii. Srimal Jayawardena et al., Image based automatic vehicle damage detection,
Ph.D. thesis
Australian National University, 2013.
iii. ​https://openei.org/datasets/dataset/gearbox-fault-diagnosis-data