com
Expert Systems
with Applications
Expert Systems with Applications 36 (2009) 31193135
www.elsevier.com/locate/eswa
Abstract
To determine the condition of an inaccessible gear in an operating machine the vibration signal of the machine can be continuously
monitored by placing a sensor close to the source of the vibrations. These signals can be further processed to extract the features and
identify the status of the machine. The vibration signal acquired from the operating machine has been used to eectively diagnose
the condition of inaccessible moving components inside the machine. Suitable sensors are kept at various locations to pick up the signals
produced by machinery and these signals are very meaningful in condition diagnosis surveillance. To determine the important characteristics and to unravel the signicance of these signals, further analysis or processing is required.
This paper presents the use of decision tree for selecting best statistical features that will discriminate the fault conditions of the gear
box from the signals extracted. These features are extracted from vibration signals. A rule set is formed from the extracted features and
fed to a fuzzy classier. The rule set necessary for building the fuzzy classier is obtained largely by intuition and domain knowledge.
This paper also presents the usage of decision tree to generate the rules automatically from the feature set. The vibration signal from a
piezo-electric transducer is captured for the following conditions good bevel gear, bevel gear with tooth breakage (GTB), bevel gear
with crack at root of the tooth (GTC), and bevel gear with face wear of the teeth (TFW) for various loading and lubrication conditions.
The statistical features were extracted and good features that discriminate the dierent fault conditions of the gearbox were selected using
decision tree. The rule set for fuzzy classier is obtained by once using the decision tree again. A fuzzy classier is built and tested with
representative data. The results are found to be encouraging.
2008 Elsevier Ltd. All rights reserved.
Keywords: Feature selection; Statistical features; Decision tree; Gear box; Fuzzy; Fault detection
1. Introduction
A faulty gear system could result in serious damage if
defects occur to one of the gears during operation condition. Early detection of the defects, therefore, is crucial to
prevent the system from malfunction that could cause damage or entire system halt. Diagnosing a gear system by
examining the vibration signals is the most commonly used
method for detecting gear failures. The conventional methods for processing measured data contain the frequency
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Feature Selection
Using J 48 Algorithm
Rule Generation
Modeling Fuzzy
system
Fuzzy inference engine
Fuzzy output
Bevel
Gear Box
Sensor
Fig. 2. Fault simulator setup.
Electromagnetic
spring loaded disc
brake
Pinion
Wheel
Gear
Wheel
Fault description
Dimension (mm)
G1
G2
G3
G4
Good
Gear tooth breakage (GTB)
Gear with crack at root (GTC)
Gear with face wear
8
0.8 0.5
0.5
Table 2
Gear wheel and pinion details
Parameters
Gear wheel
Pinion wheel
No. of teeth
Module
Normal pressure angle ()
Shaft angle ()
Top clearance (mm)
Addendum (mm)
Whole depth (mm)
Chordal tooth thickness (mm)
Chordal tooth height (mm)
Material
35
2.5
20
90
0.5
2.5
5.5
3.930.150
2.53
EN8
25
2.5
20
90
0.5
2.5
5.5
3.920.110
2.55
EN8
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Fig. 4. (a)View of good pinion wheel. (b) View of pinion wheel with face wear (GFW). (c) View of pinion wheel with tooth breakage (GTB).
-0.2
6000
-0.4
-0.4
8000
2000
4000
6000
-0.2
8000
-0.2
4000
6000
0
-0.2
2000
2000
4000
6000
Amplitude
-0.1
0
-0.1
8000
Sample No.
GTC-HalfLub-Unload
2000
4000
6000
-0.1
4000
6000
-0.1
8000
2000
4000
6000
-0.1
0
2000
4000
Sample No.
6000
8000
-0.1
2000
4000
6000
2000
8000
Sample No.
4000
6000
8000
2000
4000
6000
0
-0.2
-0.4
8000
2000
TFW-Dry-Unload
0
4000
6000
0
-0.2
0
-0.2
6000
-0.2
4000
6000
Sample
6000
8000
0
-0.2
0
2000
4000
6000
8000
Sample
TFW-FullLub-FullLoad
2000
4000
0.2
8000
0.2
2000
Sample
TFW-HalfLub-FullLoad
4000
8000
0.2
8000
0.2
2000
6000
TFW-Dry-FullLoad
-0.2
2000
4000
Sample No.
Sample
TFW-FullLub-Unload
Sample No.
GTB-FullLub-FullLoad
0.2
Amplitude
Amplitude
0
-0.2
-0.4
8000
-0.2
8000
0.1
8000
0.2
Sample No.
GTC-FullLub-FullLoad
0.1
6000
6000
0.2
Sample
TFW-HalfLub-Unload
Sample No.
GTC-FullLub-Unload
4000
Amplitude
Amplitude
2000
4000
Sample No.
GTB-HalfLub-FullLoad
0.2
8000
0.1
2000
Sample No.
GTC-HalfLub-FullLoad
0.1
-0.4
2000
Sample No.
GTC-Dry-fullLoad
Sample No.
GTB-FullLub-Unload
8000
0.1
Amplitude
Amplitude
6000
0
-0.2
-0.4
8000
-0.2
Sample No.
GTC-Dry-Unload
Amplitude
4000
6000
-0.4
0
8000
4000
0.2
8000
0.2
Sample No.
c 0.1
6000
Amplitude
Amplitude
Amplitude
2000
4000
2000
0.2
Sample No.
GTB-HalfLub-Unload
Sample No.
Good-Full-FullLoad
0.2
2000
8000
Sample No.
Good-FullLub-Unload
Amplitude
6000
0.2
-0.2
-0.4
4000
Sample No.
Good-HalfLub-FullLoad
0.2
Amplitude
Amplitude
Sample No.
Good-HalfLub-Unload
2000
Amplitude
4000
0
-0.2
Amplitude
2000
-0.2
Amplitude
GTB-Dry-FullLoad
Amplitude
GTB-Dry-Unload
0.2
Amplitude
0.2
Amplitude
Amplitude
0.2
-0.4
Good-Dry-FullLoad
Amplitude
Good-Dry-Unload
Amplitude
Amplitude
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8000
0.2
0
-0.2
0
2000
4000
6000
8000
Sample
Fig. 5. (a) Vibration signal for good pinion wheel under dierent lubrication and loading conditions. (b) Vibration signal for pinion wheel with teeth
breakage under dierent lubrication and loading conditions. (c) Vibration signal for pinion wheel with crack at root under dierent lubrication and
loading conditions. (d) Vibration signals for pinion wheel with teeth face wear under dierent lubrication and loading conditions.
in the data le. The raw vibration signals acquired for various experimental conditions form the gearbox using FFT
are shown in Fig. 5.
conditions and fed as an input to J 48 algorithm for selecting the best features which classify the dierent fault
conditions.
3. Feature extraction
4. Descriptive statistics
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4.2. Skewness
4.3. Kurtosis
Kurtosis indicates the atness or the spikiness of the signal. Its value is very low for good bevel gearbox and high
for faulty gearbox due to the spiky nature of the signal
(
Kurtosis
)
X xi x4
nn 1
n 1n 2n 3
s
2
3n 1
:
n 2n 3
x
x
y
y
2
y y
:
yt
P
2
n 2
x x
4.5. Sample variance
It is variance of the signal points and the following formula was used for computation of standard variance.
Sample variance
P 2
x2 x
:
nn 1
4.6. Range
It refers to the dierence in maximum and minimum signal point values for a given signal.
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in the nodes in Decision Tree in descending order of importance. It is to be stressed here that only features that contribute to the classication appear in the Decision Tree
and others do not. The level of contribution is not same
and all statistical features are not equally important. The
level of contribution by individual feature is given by a statistical measure within the parenthesis in the Decision Tree.
The rst number in the parenthesis indicates the number of
data points that can be classied using that feature set. The
second number indicates the number of samples against
this action. If the rst number is very small compared to
the total number of samples, then the corresponding features can be considered as outliers and hence ignored. Features that have less discriminating capability can be
consciously discarded by deciding on the threshold. This
concept is made use of in selecting good features. The algorithm identies the good features for the purpose of classication from the given training data set and thus reduces
the domain knowledge required to select good features
for pattern classication problem.
6. Methodology adopted for fuzzy classication
See Fig. 6.
7. Fuzzy logic (classier)
Fuzzy Logic provides a precise approach for dealing
with uncertainty. Fuzzy inference is a method that interprets the values in the input vector and, based on some
set of rules, assigns values to the output vector. The
point of fuzzy logic is to map an input space to an output space, and the primary mechanism for doing this is a
list of if-then statements called rules. Rules are the
inputs for building a fuzzy inference engine. The methodology adopted for fuzzy classication is shown in Fig. 6.
All rules are evaluated in parallel, and the order of the
rules is unimportant. The real world data do not have
sharply dened boundaries where information is often
incomplete or sometimes unreliable. In quest for precision, scientists have generally attempted to manipulate
the real world into articial mathematical models that
make no provision for gradation. Because Fuzzy Logic
provides the tools to classify information into broad,
coarse categorizations or groupings, it has innite possi-
Dry/Half/Full
No Load
Full Load
GOOD/GTC/
GTB/TFW
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Table 3
Condition
GOOD
GTC
GTB
TFW
GOOD
GTC
GTB
TFW
100
0
0
0
0
100
0
0
0
0
100
0
0
0
0
100
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Fig. 13. Decision tree from J 48 Algorithm for dry-lub full-load condition.
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Table 4
Condition
GOOD
GTC
GTB
TFW
GOOD
GTC
GTB
TFW
100
0
0
0
0
100
0
0
0
0
100
0
0
0
0
100
Fig. 18. Decision tree from J 48 Algorithm for half-lub no-load condition.
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Fig. 21. Rule viewer for one of the test data If stderr = 0.0005, kurtosis = 10. The output is 6.25, hence the condition is GTB.
Table 5
Condition
GOOD
GTC
GTB
TFW
GOOD
GTC
GTB
TFW
100
0
0
0
0
100
0
0
0
0
100
0
0
0
0
100
1.
2.
3.
4.
If
If
If
If
(stderr
(stderr
(stderr
(stderr
is
is
is
is
Fig. 22. Decision tree from J 48 Algorithm for half-lub full-load condition.
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Fig. 26. Rule viewer for one of the test data. If Stderr = 0.0005, kurtosis = 10, minimum = 0, output1 = 6.25, i.e., the condition is GTB.
Table 6
11. Conclusion
Condition
GOOD
GTC
GTB
TFW
GOOD
GTC
GTB
TFW
100
0
0
0
0
100
0
0
0
0
100
0
0
0
0
100
Fig. 27. Decision tree from J 48 Algorithm for full-lub no-load condition.
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Fig. 30. Rule viewer for one of the test data.If stderr = 0.0005, variance = 0.005, then output1 = 6.25.
Table 7
Condition
GOOD
GTC
GTB
TFW
GOOD
GTC
GTB
TFW
96
0
10
0
0
100
0
0
0
0
90
0
4
0
0
100
the gearbox fault identication based on fuzzy logic technique, shows the great potentiality and the strong ability
to classify and identify machinery faults. This work has
investigated the use of basic fuzzy logic principle as a fault
diagnostic technique for spur bevel gearbox. The work conducted has demonstrated the potential of fuzzy logic to
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Fig. 31. Decision tree from J 48 Algorithm for full-lub full-load condition.
Fig. 33. Rule viewer for one of the test data. If stderr = 0.0002 then output1 = 1.25, ie, the condition is Good.
GOOD
GTC
GTB
TFW
GOOD
GTC
GTB
TFW
100
0
0
0
0
100
0
0
0
0
100
0
0
0
0
100
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