Nonlinear Engineering 2021; 10: 404–413
Zhe Mi, Tiangang Wang, Zan Sun, and Rajeev Kumar*
Vibration signal diagnosis and analysis of rotating
machine by utilizing cloud computing
https://doi.org/10.1515/nleng-2021-0032
Received Jul 6, 2021; accepted Sep 17, 2021.
Abstract: Vibration signal diagnosis and analysis plays
an important role in the industrial machinery since it en-
hances the machinery performance under supervision.
The information regarding the future condition is given
by vibration diagnosis techniques which is growing inter-
est for the scientific and industrial communities. Informa-
tion for failure diagnostic and prediction are provided by
the motor vibration through signal processing. The devel-
opment of mechanical systems fault prognosis and in the
last decades, research is done at a very rapid rate. The ex-
amination of vibration signal monitoring is done in this
paper with the aid of Cyber-Physical Systems (CPS) and
Cloud Technology (CT). The machines maintenance strate-
gies are implemented by using the data collected from ma-
chines which are based on the fault prognosis. The cloud
computing platform is presented in this paper which is
having three layers and the unlabelled data is received to
generate an interpreted online decision. Feature extrac-
tion of the vibration signal is obtained in terms of range,
mean value, root mean square value, and standard devi-
ation and crest values. The performance of the model is
evaluated by utilizing the classical statistical metrics such
as RMSE Mean Absolute Error (MAE) and Mean Absolute
Percentage Error (MAPE) of the vibration signal. It is ob-
tained that the proposed technique is 25% and 90% bet-
ter than the Adaptive Neurofuzzy Inference System and the
Single Modeling System respectively in terms of RMSE. The
performance in terms of MAPE, then the proposed tech-
nique outperforms the existing Adaptive Neurofuzzy In-
ference System and the Single Modeling System by 8 %
and 60% respectively. The presented technique is better
than the existing Adaptive Neurofuzzy Inference System
and the Single Modeling techniques by average of 15% and
30 % respectively.
Keywords: Vibration signal; cloud technology; cyber-
physical systems; diagnosis and prognosis; rapid rate;
mean absolute error; single modeling system
Open Access. © 2021 Zhe Mi et al., published by De Gruyter.
alone 4.0 License.
1 Introduction
The productivity loss, time loss, safety and environment
problems are resulted by the industrial equipment fail-
ure. The organization’s manufacturing operations are re-
quired to be maintained and it is important for availability
and reliability of product and production facilities [1, 2].
The maintenance gained less attention as compared to
the manufacturing problems and it leads to low mainte-
nance efficiency in industry. The equipment maintenance
is very important and critical aspect as the maintenance
activities carried by the traditional reactive maintenance
only after failure detection. About the periodicity of fail-
ure, the periodic maintenance activities are implied by
the widespread preventive maintenance. Predictive main-
tenance is required for cost saving and to prevent the fail-
ure of equipment. For various industries, motors are es-
sential and are used for various applications such as elec-
tric generators, window lifting motor, etc. Sample of motor
is shown in Figure 1. There is an unexpected stop if there
are failures in the motor and loss of production time and
money is caused by it. The online condition monitoring is
developed by the researchers to avoid the motor failure.
The fault diagnosis techniques are used for the detection of
faults and to provide the diagnostic information of motors.
Vibrations signals depend on the motor states and fault is
connected with vibration signals [3–6]. For fault diagno-
sis, characteristic frequencies and the states of the motor
correlation is required.
The early fault diagnostic methods detect the early
fault state and sometimes the motor is damaged in only 5
minutes by short-circuiting. For the permanently damage
of motor, faults like air-gap, and broken rotor take much
time [7, 8]. The analysis of diagnostic signals is done by the
Zhe Mi, Tiangang Wang, Baoding Vocational and Technical Collage,
Baoding 071051, China, E-mail: Miezhe1010@outlook.com, wang-
tiangang211@outlook.com
Zan Sun, Baoding University, Baoding 071000, China, E-mail:
sunzan677@outlook.com
*Corresponding Author: Rajeev Kumar, Chitkara University Institute
of Engineering and Technology, Chitkara University, Punjab, India,
E-mail: rajeev_chauhan364@yahoo.co.in
This work is licensed under the Creative Commons Attribution
 Zhe Mi, Tiangang Wang, Zan Sun, and Rajeev Kumar, Vibration signal diagnosis and analysis
condition monitoring of electric motors. Measurements of
acoustic signal and thermal signal can be done without
touching the motor.
Figure 1: Sample of motor in industries
The fault diagnosis is performed by the model-based
methods which are relied on analytical redundancy and
analytical models expect the process behavior. The math-
ematical model is exploited by analytical models of the
monitored machine [9]. The residual generation methods
based on this explicit model are utilized to obtain signals
which are indicative of fault presence in the machine. The
vibration signals i.e., the residuals evaluation; the fault de-
tection and isolation are achieved as shown in Figure 2.
Figure 2: Basic block diagram of fault diagnosis
The linear system models, process models and behav-
ioral models have been examined and included in vari-
ety of models [10–13]. The faults diagnosing of mechani-
cal system components such as bearings rotors are applied
for model-based methods. A model is built accurately by
model-based approaches effectively.
Research gaps: Information for failure diagnostic and
prediction are provided by the motor vibration through sig-
nal processing. The fault alarm systems examination and
monitoring are not effective in terms of mean value, root
mean square value, and standard deviation.
Contribution:
a. The examination and monitoring of alarm systems,
with the aid of Cloud Technology (CT).
b. Implementation based on the machines fault progno-
sis by utilizing the machines’ data collection.
| 405
c. The cloud computing platform having three layers and
the unlabelled data are received to interpreted online
decision generation.
d. Feature extraction of the vibration signal is obtained
in terms of range, mean value, root mean square
value, and standard deviation and crest values.
The rest of the paper is organized as follows. Section
2 provides an overview of the exhaustive literature survey
followed by a methodology adopted in section 3. A detailed
discussion of obtained results is in section 4. Finally, con-
cluding remarks are provided in Section 5.
2 Literature review
Many researchers have worked on the motor vibration di-
agnosis based on cloud computing in the previous years.
The electric motors are monitored in real-time; the au-
thor details the testing of an Industrial Internet of Things
(IIoT) system [14]. For the capability comparison, the fre-
quency domain analysis is carried out in the gateway. The
edge and fog computing is advantageous which is carried
by the complement to cloud computing. In an industrial
dairy plant, testing of the prototype is done in the labo-
ratory. The author presents the diagnosing failures in ro-
tary machines method by utilizing the Machine Learning
techniques [15]. For fault diagnosis of the rotational un-
balance, author proposed a support vector machine algo-
rithm in the rotor. For vibration analysis, the most popular
classification methods is support vector machines (SVMs).
The vibration-based fault diagnosis techniques are pre-
sented by the author in this paper which is based on the
motor [16]. The signal processing methods and the vibra-
tion signals are utilized by the proposed method. The three
states of healthy CM, CM with broken tooth on sprocket,
CM with broken rotor coil recognition efficiency are ana-
lyzed by the authors. The prediction through signal pro-
cessing and the information for failure diagnostic are pro-
vided by the motor vibration [17]. The IoT-based monitor-
ing system is presented by the author in this paper for
recording the vibration of the induction motor. The vibra-
tion data from the motor is collected by the 27mm piezo-
electric. The 3 scenarios experiments are conducted for
the vibration data collection from different positions. The
recorded vibration is sent by the each node vibration to the
cloud with an average delay of 1 sec.
In the last few decades, fault prognosis have been re-
searched and developed in mechanical systems at a very
rapid rate [18]. The approaches-based fault diagnosis and
406 | Zhe Mi, Tiangang Wang, Zan Sun, and Rajeev Kumar, Vibration signal diagnosis and analysis

prognosis are investigated in this paper by the authors and

predictive maintenance knowledge is obtained. For fault
3 Methodology
prognosis, the applications of the data mining methods
The motor monitoring status is detected by the several
are illustrated in the case study. The author in this paper
types of data collection methods. There are different types
presents a remote observing system dependent on Inter-
of signals from which the vibration signal is the common
net of Things (IoT) for protected and economic data com-
fault detection technique. The vibration signal is analyzed
munication [19]. The parameters like Temperature, vibra-
and illustrated here in this section.
tions, speed, motor current and voltage of induction ma-
chine are screened by the module of transducers and sen-
sors. The Automatic ON/OFF for faulty conditions is addi-
3.1 Analysis of vibration signal features
tionally presented by the system which shows the informa-
tion on LCD show and data is passed on. The model gives
The feature extraction is the vibration signal’s first step.
information to WIFI IoT applications to make the system
The rotating system failure status is diagnosed by these
quick and easy to understand. Due to the potential advan-
forms [23–25]. The diagnosis technique’s accuracy is im-
tages, the considerable subjects of system are the Machine
proved by extracting the hidden data. The times domains
fault prognostic techniques [20]. There is rapid growth
feature calculation from the vibration signal areas given in
from the past few years in the machine fault diagnosis and
equations.
prognosis. The wide range of statistical approaches is cov-
ered by the publications to model-based approaches. Also, Range (R) = max(y i ) − min(y i ) (1)
the challenges and the opportunities are also discussed
in machine prognosis field. Author details the consider- PN
able condition-based maintenance system i.e., faults prog- i=1 yi
Mean Value (M) = (2)
nostic techniques of machine [21]. The decreasing main- N
tenance costs and increasing machine availability, poten-
s
tial advantages are gained by the maintenance strategies. P 2
(y i − y” )
There is rapid development of the machine fault diagno- Standard Deviation (D) = (3)
(N − 1)
sis and prognosis research. The recent published tech-
niques in diagnosis and prognosis of rotating machinery v
are summarized and classified by synthesizing and pro-
u
u1 XN

viding the information of these researches. In the field Root Mean Square (RMS) = t (y i − y” )2 (4)
N
i=1
of machine prognosis, various challenges and the oppor-
tunities are discussed by the authors for conducting ad-
vance research. The machine vision, feature extraction, max (y i )
Crest Factor = (5)
and support vector machine (SVM) are utilized and de- RMS
tailed by the authors in this study for the vibration mon-
itoring system (VMS) to composition [22]. A vision-based PSNR = 10 * log10 (2n − 1)2 /MSE (6)
data-driven methodology is presented by the author for
industrial robot health assessment. The experimental evi-
Structural Similarity Index (SSIM) =
dence of the methodology is provided on the system which
comprises the five binary squared fiducial markers and two (2µx µy + c1) (2σx, y + c2)
(7)
µ2x + µ2Y + C1 σ2X + σ2Y + C2



monocular cameras. The deviation of the end-effect or is
accurately tracked by the fiducial marker system. The tra- µ x and µ y = average of x and y.
jectory deflection is monitored by utilizing the weights at- σ2 x and σ2 y = variance of x and y.
tached to the end-effect or [23]. The supervised learning re- σ x,y = Covariance of x and y.
gression models are trained by tracing the trajectory infor-
mation. The presented protocol is robust, rigorous and re-
liable and identifies the mechanical element that produces 3.2 The clustering analysis
the non-kinematic errors. The presented VMS technique’s
experiment setup is straightforward and the surveillances The vibration signal information is illustrated and the
are cooperated in industrial environments. nodes are found between the classes by feature utilization
 Zhe Mi, Tiangang Wang, Zan Sun, and Rajeev Kumar, Vibration signal diagnosis and analysis
Figure 3: Clustering analysis
after the vibration signals analysis. Basic clustering analy-
sis presentation is shown in Figure 3. The homogenous ob-
jects are characterized by the clustering analysis deal with
the complex data-sets.
The best clusters are obtained by the K-mean cluster-
ing as it is commonly utilized algorithm [26–28]. The sums
of squared distances are minimized by the clustering pro-
cess. Some steps are utilized by this technique.
1. The randomness of K centroid is the initial based.
2. To the nearest centroid, each point of the dataset is al-
located.
3. Each data point is recomputed to the cluster of cen-
troid cluster for intra-cluster reduction.
3.3 Logical Analysis of Data (LAD)
The pattern recognition based phenomena is allowed by
data-driven LAD technique, training and testing are the
two stages which are applied. The data is utilized as train-
ing data for patterns extraction [29]. The training data is
well balanced to build the diagnosis model for healthy and
failure classes.
3.4 Data binarization
By using a binarization technique, the transformation of
raw data into binary data in which each numerical feature
is translated into the set of binary attributes. The data set
in ascending order are utilized by the binarization tech-
nique [30]. Between every two values, the cut point is in-
serted and then the average is calculated, value as shown
| 407
in equation.
( )
1 if u ≥ α
b(u) = (8)
0 if u < α
3.5 Pattern generation
The formulation of a mixed-integer and linear program-
ming based on pattern generation. The discriminating
powers between the different classes are controlled by the
approach [31]. By the pattern generation algorithm, the
generated number of patterns has no limit to create more
patterns finding possibilities.
3.6 Unlabelled remote diagnosis system
architecture
In maintenance innovation, Cloud technologies (CT) are
becoming the trend for the machines maintenance and
industrial process. CT is cost effective and has merits of
unlimited storage space and security. The machines are
required to be continuously monitored for the achieve-
ment of near-zero breaks down [32–34]. The architecture of
cyber-physical system maintenance is detailed in Figure 3.
1) Sensor Layer: The multisource unlabelled data is pro-
vided by the sensors consisted in the sensor layer. The
wireless communication capability of the sensor enables
the data transfer for the decision making layer [35]. The
machining process is reported by the intelligent sensors
and shares with the process controller.
2) Connection layer: The file storage distribution and par-
allel computing is consisted in this layer. The physical and
the cyber side connection occur by CT utilization [36, 37].
3) Decision-making layer: The unlabelled data is then
transferred by the analyzer software and then sent back
to the maintenance team.
The internet-based services which are cloud services
offer all the things that are provided by the computer sys-
tem. There is an overwhelming data flow due to the data
collation increment and CT has the merits of virtualized re-
sources and data service integrated with scalable storage
of data. The best performance is provided by the virtual-
ized machine with low cost. Figure 4 shows the unlabelled
cyber-physical system’s proposed architecture.
The sensor in the model takes a monitored machine
signal. The online remote diagnosis center converts the
collected unlabelled data into the useful data and then the
status of the machine is determined. An alarm and correc-
tive action are sent by the system to prepare the required
element. The system accuracy is improved by the cloud.
408 | Zhe Mi, Tiangang Wang, Zan Sun, and Rajeev Kumar, Vibration signal diagnosis and analysis

Figure 6: Mean values (M) of the different samples

Figure 4: Cyber-physical system

Figure 7: Standard Deviation (SD) of the different samples

4 Results and discussion

4.1 Analysis of the system

To test and analyze the system, there is a development of

cyber-physical maintenance system of rolling element fail-
ure simulation model to test the system. The samples of the
datasets are publically available and can access online. A
snapshot of the vibration signal is collected by the card un-
Figure 8: Root Mean Square (RMS) of the different samples
til a failure occurred. Table 1 illustrates feature extraction
using MATLAB Software.
The vibration signal feature extraction is tabulated in
above table in terms of range, mean, standard deviation,
root mean square and the crest values. For better visual-
ization and analysis these obtained values are graphically
represented in Figures 5-9 for different samples.

Figure 9: Crest Factor (CF) of the different samples

tics patterns by using the new data after clustering as ex-

Figure 5: Range values (M) of the different samples
A healthy or unhealthy condition is lead by the ma-
chine operation status after detecting by the characteris-
hibited in Table 2. The negative patterns in the condition
of health status are discovered by positive patterns as gen-
erated by LAD.
The quality of the healthy and unhealthy class is pre-
sented graphically in Figure 10.
The data set file sent the vibration signal to the cloud
file in the Drop-box application via internet. Two centers
 Zhe Mi, Tiangang Wang, Zan Sun, and Rajeev Kumar, Vibration signal diagnosis and analysis | 409

Table 1: Feature extraction of samples

Standard
Samples Range Mean Root Mean Square Crest Factor
Deviation
1 0.834 -0.002 0.071 0.074 6.120
2 0.729 -0.019 0.073 0.079 7.621
3 0.183 -0.021 0.078 0.032 6.865
4 0.729 -0.003 0.038 0.054 6.678
5 0.319 -0.042 0.021 0.210 7.562
6 1.872 -0.038 0.359 0.261 8.572
7 3.210 -0.041 0.048 0.311 5.563
8 1.628 -0.218 0.029 0.201 6.672
9 0.873 -0.331 0.071 0.022 7.352
10 2.577 -0.214 0.063 0.182 6.563

Table 2: Results of K-mean clustering

Sample Class Quantity

1 Healthy 750
2 Unhealthy 205

provement of the offline governor patterns generation ac-

curacy. The stored historical data is used for the automatic
software update.

4.2 Statistical analysis of the signal

vibration in system

The performances of the models are assessed by utilizing

Figure 10: Quantity of healthy and unhealthy class
are included in it, the physical center and the cyber cen-
ter. The sensors, actuators and the maintenance team of
the monitoring machine are included in it. The data from
the physical center is received by the cyber center which
is then converted into the useful information for proper
monitoring and controlling of physical world. The local
maintenance team is allowed by the system to see a live
view of the running machine interaction. Additionally, the
cyber-physical system code is built by the MATLAB. The
signals are sent and received by the gateway and cyber-
physical center generates the corrective action via the in-
ternet. High scalability and lower costs are the benefits of
using this gateway. Analysis of the received data and the
generation of suitable decision, every certain time is run
by the built governing code. The positive pattern is identi-
fied and an alarm report is automatically sent by the sys-
tem including the decision and the corrective action. The
gateway carrier sent the generated decision to the machine
controller. The Drop Box file stores the data for the im-
the classical statistical metrics such as RMSE Mean Ab-
solute Error (MAE) and Mean Absolute Percentage Error
(MAPE). These are the basic and mostly used performance
metrics which are accepted by the research community.
These are used for the models development is analyzed by
the RMSE. This parameter is the amplitude sensitive. The
forecast evaluation is done by the MAE and it is insensitive
to the outliers. The mean deviation of each sample deter-
mination is done by the MAPE and amplitude normalizes
the samples. It also helps to unify the scale and can be used
to errors of signals comparison with different levels of am-
plitudes. Four scenarios have been considered for analy-
sis, that is, the healthy condition (HC), a bearing failure
(BF) condition, a half-broken rotor bar (HBRB) condition,
and full-broken rotor bar (FBRB). These different parame-
ters obtained for four different scenarios by the proposed
method as shown in Table 3. It is also represented graphi-
cally in Figure 11 for better visualization and analysis.
From the Figure 10, it is clear that the all these param-
eters are high for full broken rotor case. The RMSE, MAPE
and MAE are less for the healthy rotor. These parameters
go worse with the condition of rotor. So these parameters
are beneficial to check the condition of rotor. The quality
410 | Zhe Mi, Tiangang Wang, Zan Sun, and Rajeev Kumar, Vibration signal diagnosis and analysis
Table 3: Different parameters obtained for four different scenarios by the proposed method
Different Scenarios
RMSE
Healthy condition 0.010
Bearing failure 0.016
Half-broken rotor 0.018
Full-broken rotor bar 0.021
Figure 11: Parameters obtained for four different scenarios
parameters like SNR and SSIM are also checked to check
the performance of the technique as shown in Table 4.
Higher the value of the PSNR, higher will be the qual-
ity, the healthy condition rotor have the high PSNR value
as compared to the bearing failure, half-broken rotor and
the full-broken rotor bar. The value of SSIM is in between
the 0 and 1. If the value approaches to 1 shows the high
quality.
4.3 Comparison with other techniques
The results obtained by the presented technique for the
four different scenarios are also compared with the exist-
ing techniques for the validation purpose. Comparison of
the presented technique is done on the basis of RMSE,
MAPE and MAE as tabulated in Table 5.
From the table, it is clear that the minimum error is
obtained by the proposed technique as compared to other
existing techniques. The percentage improvement of the
proposed technique is also calculated and shown in Table
6.
The graphical representation is also shown in Figure
12 for better analysis and visualization. It is obtained that
the proposed technique is around 25% and 90% better
than the Adaptive Neurofuzzy Inference System and the
Single Modeling System respectively in terms of RMSE.
If one see the performance in terms of MAPE, then
the proposed technique outperforms the existing Adaptive
Proposed Method
MAPE (%) MAE
1.55 0.112
2.18 0.120
2.70 0.129
3.35 0.134
Figure 12: Percentage improvement of the proposed technique over
existing techniques
Neurofuzzy Inference System and the Single Modeling Sys-
tem by 8% and 60%, respectively. The presented technique
is better than the existing Adaptive Neurofuzzy Inference
System and the Single Modeling techniques by average of
15% and 30%, respectively.
Applications: Development of fault diagnosis and prog-
nosis strategies that achieved extensive utility in a wide
range of application domains in recent years. Typically,
there are two major classes: Model based and data-driven.
A model-based technique depends on dynamic system
model accuracy. It uses actual technique for generation
of the difference between the two outputs, indicative of a
fault condition.
The anticipated fault condition is addressed by the
data-driven techniques where a fault model collects the
constructs like neural networks which must be trained first
with prototype fault patterns.
5 Conclusion
The diagnosis of machine performance is done by build-
ing the Maintenance-CPS platform and unlabelled data is
explored. The expert’s expensive onsite visit, reduction
of training cost and the non-zero breakdown is achieved
by the continuous monitoring; these are the merits of the
proposed system. The proposed layers of cyber-physical
 Zhe Mi, Tiangang Wang, Zan Sun, and Rajeev Kumar, Vibration signal diagnosis and analysis | 411

Table 4: PSNR and SSIM obtained for four different scenarios by the proposed method

Different Scenarios Proposed Method

PSNR (dB) SSIM
Healthy condition 56 0.92
Bearing failure 49 0.88
Half-broken rotor 40 0.79
Full-broken rotor bar 34 0.71

Table 5: Comparison of the presented technique over existing techniques

Adaptive Neurofuzzy Single Modeling

Different Scenarios Proposed Method
Inference System [38] System [38]
MAPE MAPE MAPE
RMSE MAE RMSE MAE RMSE MAE
(%) (%) (%)
Healthy condition 0.013 1.69 0.135 0.203 3.45 0.129 0.010 1.55 0.112
Bearing failure 0.020 2.27 0.125 0.275 6.77 0.265 0.016 2.18 0.120
Half-broken rotor 0.022 2.82 0.133 0.478 6.92 0.184 0.018 2.70 0.129
Full-broken rotor bar 0.025 3.44 0.139 0.394 8.93 0.192 0.021 3.35 0.134

Table 6: Percentage improvement of the proposed technique over existing techniques

Different Scenarios Percentage Improvement of the Proposed Technique

In terms of RMSE over In terms of MAPE over In terms of MAE over
Adaptive Adaptive
Single Single Adaptive Neuro Single
Neuro-fuzzy Neuro-fuzzy
Modeling Modeling fuzzy Inference Modeling
Inference Inference
System System System System
System System

Healthy condition 30.00 % 95.07% 9.03% 55.07% 20.54% 13.18%

Bearing failure 25.00% 94.18% 4.13% 67.80% 4.17% 54.72%
Half-broken rotor 22.22% 96.23% 4.44% 60.98% 3.10% 29.89%
Full-broken rotor bar 19.05% 94.67% 2.69% 62.49% 3.73% 30.21%

system are connected to the Cloud technologies. The
different layers of the system are sensor, analysis, and
decision making. Based on an interpretable method deal-
ing with data, decision making and analysis is done. The
rolling element bearing are used to test the presented sys-
tem. Finally, the cloud technologies and the future fault
prognosis systems maintenance field are discussed. The
performances of the models are evaluated by utilizing the
classical statistical metrics such as RMSE Mean Absolute
Error (MAE) and Mean Absolute Percentage Error (MAPE).
It is obtained that the proposed technique is around 25%
and 90% better than the Adaptive Neurofuzzy Inference
System and the Single Modeling System respectively
in terms of RMSE. Higher the PSNR, higher will be the
quality, the healthy condition rotor have the high PSNR
value as compared to the bearing failure, half-broken rotor
and the full-broken rotor bar. The future work will focus
on the development of an automatic anomaly detection in
the gateway.
Funding information: The authors state no funding
involved.
Author contributions: All authors have accepted re-
sponsibility for the entire content of this manuscript and
approved its submission.
Conflict of interest: The authors state no conflict of inter-
est.
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