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The purpose of this paper is to report the findings of a study that used measurements of shaft relative rotational position, made using inexpensive Hall Effect sensors and magnets mounted at the ends of a gearbox input and output shafts, to determine gear “transmission variance.” The transmission variance signals, as a function of gear/shaft rotational position, were then used to detect and diagnose gear faults.

Two sets of spur gears (one plastic and one steel) were used to experimentally determine the relative shaft rotational position between the input and the output gearbox shafts. Fault-free and faulted (damaged tooth faces and cracked tooth bases) gears were used to collect representative dynamic signals. Signal processing was used to extract transmission variance values as a function of shaft rotational position and then used to detect and diagnose gear faults.

The results show that variations in the relative rotational position of the output shaft relative to that of the input shaft (the transmission variance) can be used to reveal gear mesh characteristics, including faults, such as cracked or missing gear teeth and flattened gear tooth faces, in both plastic gears and steel gears under appropriate (realistic) loads and speeds.

The operational mode of the non-contact rotational position sensors and the dynamic accuracy limitations are explained along with the basic signal processing required to extract transmission variance values.

The results show that shaft rotational position measurements can be made accurately and precisely using relatively inexpensive sensors and can subsequently reveal gear faults.

The inexpensive and yet trustworthy fault detection methodology developed in this work should help to improve the efficiency of maintenance actions on gearboxes and, therefore, improve the overall industrial efficiency of society.

The method described has distinct advantages over traditional analysis methods based on gearbox vibration and/or oil analysis.

The purpose of this paper is to detect gears' faults with an automatic decision‐making process and find a reliable method to detect faults on gear systems using a composition of conventional methods.

First, the vibration behavior of gears during engagement is investigated. Then, after studying different methods of fault detection using vibration signals analysis, a suitable method is proposed for the case of gears. For this purpose, a fuzzy model is employed based on available knowledge about fault detection of gears and results obtained from vibration behavior of gears. In the mentioned fuzzy model, a feature extracted from wavelet transform and also a couple of statistical indexes are used as fault criteria.

Using fuzzy systems instead of numerous data in training the decision‐making system and also utilizing available knowledge of gears' signals and information of fault effects can significantly simplify the decision‐making process in auto‐detecting gears faults, considering difficulty of laboratory set up, manufacturing and different faults creation, as well as, lack of sufficient data.

In order to validate and enhance the proposed model, an empirical set up is manufactured and tested. Later on, the model is tested on another set of gears.

Although the gears' faults were completely different from those of experimental set up, promising results in detecting faults were obtained. Moreover, it is shown that it is possible to determine the level of gears' health, as well as to estimate the gears' status, owing to fuzzy logic. This issue can be observed in the change of fault parameter while analyzing signals related to the fault growth in gears.

The purpose of this paper is to present an actuator fault detection method for unmanned aerial vehicles (UAVs) based on interval observer and extended state observer.

The proposed algorithm has very little model dependency. Therefore, a six-degree-of-freedom linear equation of UAVs is first established, and then, combined with actuator failure and external disturbances in flight control, a steering gear model with actuator failure (such as stuck bias and invalidation) is designed. Meanwhile, an extended state observer is designed for fault detection. Moreover, a fault detection scheme based on interval observer is designed by combining fault and disturbances.

The method is testified on the extended state observer and the interval observer under the failure of the steering gear and bounded disturbances. The simulation results show that the two types of fault detection schemes designed can successfully detect various types of faults and have high sensitivity.

This research paper studies the failure detection scheme of the UAVs’ actuator. The fault detection scheme in this paper has better performance on actuator faults and bounded disturbances than using regular fault detection schemes.

The purpose of this paper is to suggest new method for improving the condition indicators (CIs) used in health and usage monitoring system based on signal separation of gears.

The research method is based on employing signal separation techniques to improve gears signal and fault signature. The signal separation is based on adaptive filters concept.

CIs estimated for the deterministic part of vibration signal show higher sensitivity to gears faults in comparison to indicators estimated based on the original signal. This method proposed could enhance early fault detection in gears, particularly for those applications where strong background noise from other sources in the machine masks the characteristics fault components.

The contribution of this research is improving the CIs currently used for helicopter gearboxes. As consequence the safe operation and availability will be improved.

The purpose of this paper is to study the fault diagnosis of internal combustion (IC) engine gearbox using vibration signals with signal processing and machine learning (ML) techniques.

Vibration signals from the gearbox are acquired for healthy and induced faulty conditions of the gear. In this study, 50% tooth fault and 100% tooth fault are chosen as gear faults in the driver gear. The acquired signals are processed and analyzed using signal processing and ML techniques.

The obtained results show that variation in the amplitude of the crankshaft rotational frequency (CRF) and gear mesh frequency (GMF) for different conditions of the gearbox with various load conditions. ML techniques were also employed in developing the fault diagnosis system using statistical features. J48 decision tree provides better classification accuracy about 85.1852% in identifying gearbox conditions.

The proposed approach can be used effectively for fault diagnosis of IC engine gearbox. Spectrum and continuous wavelet transform (CWT) provide better information about gear fault conditions using time–frequency characteristics.

In this paper, experiments are conducted on real-time running condition of IC engine gearbox while considering combustion. Eddy current dynamometer is attached to output shaft of the engine for applying load. Spectrum, cepstrum, short-time Fourier transform (STFT) and wavelet analysis are performed. Spectrum, cepstrum and CWT provide better information about gear fault conditions using time–frequency characteristics. ML techniques were used in analyzing classification accuracy of the experimental data to detect the gearbox conditions using various classifiers. Hence, these techniques can be used for detection of faults in the IC engine gearbox and other reciprocating/rotating machineries.

Usually, the machinery in process plants is exposed to harsh and uncontrolled environmental conditions. Even after taking different types of preventive measures to detect and isolate the faults at the earliest possible opportunity becomes a complex decision-making process that often requires experts’ opinions and judicious decisions. The purpose of this paper is to propose a framework to detect, isolate and to suggest appropriate maintenance tasks for large-scale complex machinery (i.e. gearboxes of steel processing plant) in a simplified and structured manner by utilizing the prior fault histories available with the organization in conjunction with case-based reasoning (CBR) approach. It is also demonstrated that the proposed framework can easily be implemented by using today’s graphical user interface enabled tools such as Microsoft Visual Basic and similar.

CBR, an amalgamated domain of artificial intelligence and human cognitive process, has been applied to carry out the task of fault detection and isolation (FDI).

The equipment failure history and actions taken along with the pertinent health indicators are sufficient to detect and isolate the existing fault(s) and to suggest proper maintenance actions to minimize associated losses. The complex decision-making process of maintaining such equipment can exploit the principle of CBR and overcome the limitations of the techniques such as artificial neural networks and expert systems. The proposed CBR-based framework is able to provide inference with minimum or even with some missing information to take appropriate actions. This proposed framework would alleviate from the frequent requirement of expert’s interventions and in-depth knowledge of various analysis techniques expected to be known to process engineers.

The CBR approach has demonstrated its usefulness in many areas of practical applications. The authors perceive its application potentiality to FDI with suggested maintenance actions to alleviate an end-user from the frequent requirement of an expert for diagnosis or inference. The proposed framework can serve as a useful tool/aid to the process engineers to detect and isolate the fault of large-scale complex machinery with suggested actions in a simplified way.

This study aims to bring awareness to the developing of fault detection systems using the data collected from sensor devices/physical devices of various systems for predictive maintenance. Opportunities and challenges in developing anomaly detection algorithms for predictive maintenance and unexplored areas in this context are also discussed.

For conducting a systematic review on the state-of-the-art algorithms in fault detection for predictive maintenance, review papers from the years 2017–2021 available in the Scopus database were selected. A total of 93 papers were chosen. They are classified under electrical and electronics, civil and constructions, automobile, production and mechanical. In addition to this, the paper provides a detailed discussion of various fault-detection algorithms that can be categorised under supervised, semi-supervised, unsupervised learning and traditional statistical method along with an analysis of various forms of anomalies prevalent across different sectors of industry.

Based on the literature reviewed, seven propositions with a focus on the following areas are presented: need for a uniform framework while scaling the number of sensors; the need for identification of erroneous parameters; why there is a need for new algorithms based on unsupervised and semi-supervised learning; the importance of ensemble learning and data fusion algorithms; the necessity of automatic fault diagnostic systems; concerns about multiple fault detection; and cost-effective fault detection. These propositions shed light on the unsolved issues of predictive maintenance using fault detection algorithms. A novel architecture based on the methodologies and propositions gives more clarity for the reader to further explore in this area.

Papers for this study were selected from the Scopus database for predictive maintenance in the field of fault detection. Review papers published in this area deal only with methods used to detect anomalies, whereas this paper attempts to establish a link between different industrial domains and the methods used in each industry that uses fault detection for predictive maintenance.

Bearings and gears are major components in any rotatory machines and, thus, gained interest for condition monitoring. The failure of such critical components may cause an increase in down time and maintenance cost. Condition monitoring using the machine learning approach is a conceivable solution for the problem raised during the operation of the machinery system. The paper aims to discuss these issues.

This paper aims engine gearbox fault diagnosis based on a decision tree and artificial neural network algorithm.

The experimental result (classification accuracy 85.55 percent) validates that the proposed approach is an effective method for engine gearbox fault diagnosis.

This paper attempts to diagnose the faults in engine gearbox based on the machine learning approach with the combination of statistical features of vibration signals, decision tree and multi-layer perceptron neural network techniques.

In gearbox fault diagnosis, identifying the fault type and severity simultaneously, as well as the compound fault containing multiple faults, is necessary.

To diagnose multiple faults simultaneously, this paper proposes a multichannel and multi-task convolutional neural network (MCMT-CNN) model.

Experiments were conducted on a bearing dataset containing different fault types and severities and a gearbox compound fault dataset. The experimental results show that MCMT-CNN can effectively extract features of different tasks from vibration signals, with a diagnosis accuracy of more than 97%.

Vibration signals at different positions and in different directions are taken as the MC inputs to ensure the integrity of the fault features. Fault labels are established to retain and distinguish the unique features of different tasks. In MCMT-CNN, multiple task branches can connect and share all neurons in the hidden layer, thus enabling multiple tasks to share information.

The developments of complex systems have increased the demand for condition monitoring techniques so as to maximize operational availability and safety while decreasing the costs. Signal analysis is one of the methods used to develop condition monitoring in order to extract important information contained in the sensory signals, which can be used for health assessment. However, extraction of such information from collected data in a practical working environment is always a great challenge as sensory signals are usually multi-dimensional and obscured by noise. The paper aims to discuss this issue.

This paper presents a method for trends extraction from multi-dimensional sensory data, which are then used for machinery health monitoring and maintenance needs. The proposed method is based on extracting successive features from machinery sensory signals. Then, unsupervised feature selection on the features domain is applied without making any assumptions concerning the source of the signals and the number of the extracted features. Finally, empirical mode decomposition (EMD) algorithm is applied on the projected features with the purpose of following the evolution of data in a compact representation over time.

The method is demonstrated on accelerated degradation data set of bearings acquired from PRONOSTIA experimental platform and a second data set acquired form NASA repository.

The method showed that it is able to extract interesting signal trends which can be used for health monitoring and remaining useful life prediction.