Sound-Based Unsupervised Fault Diagnosis of Industrial Equipment Considering Environmental Noise

The influence of environmental noise is generally excluded during research on machine fault diagnosis using acoustic signals. This study proposes a fault diagnosis method using a variational autoencoder (VAE) and domain adaptation neural network (DANN), both of which are based on unsupervised learning, to address this problem. The proposed method minimizes the impact of environmental noise and maintains the fault diagnosis performance in altered environments. The fault diagnosis algorithm was implemented using acoustic signals containing noise, present in the malfunctioning industrial machine investigation and inspection open dataset, and the fault prediction performance in noisy environments was examined based on forklift acoustic data using the VAE and DANN. The VAE primarily learns from normal state acoustic data and determines the occurrence of faults based on reconstruction error. To achieve this, statistical features of Mel frequency cepstral coefficients were extracted, generating features applicable regardless of signal length. Additionally, features were enhanced by applying noise reduction techniques via magnitude spectral subtraction and feature optimization, reflecting the characteristics of rotating equipment. Furthermore, data were augmented using generative adversarial networks to prevent overfitting. Given that the forklift acoustic data possess time-series characteristics, the exponentially weighted moving average was determined to quantitatively track time-series changes and identify early signs of faults. The VAE defined the reconstruction error as the fault index, diagnosing the fault states and demonstrating excellent performance using time-series data. However, the fault diagnosis performance of the VAE tended to decrease in noisy environments. Moreover, applying DANN for fault diagnosis significantly improved diagnostic performance in noisy environments by overcoming environmental differences between the source and target domains. In particular, by adapting the model learned in the source domain to the target domain and considering the domain differences based on signal-to-noise ratio, high diagnostic accuracy was maintained regardless of the noise levels. The DANN evaluated interdomain similarity using cosine similarity, enabling the accurate classification of fault states in the target domain. Ultimately, the combination of the VAE and DANN techniques enabled effective fault diagnosis even in noisy environments.