Vibration and Stray Flux Signal Fusion for Corrosion Damage Detection in Rolling Bearings Using Ensemble Learning...

Area of Science:

• Mechanical Engineering
• Electrical Engineering
• Materials Science

Background:

• Induction motors are vital industrial components, but bearing corrosion, often caused by humidity and heat, leads to performance degradation and costly failures.
• Early diagnosis of bearing corrosion is challenging due to its diffuse nature, unlike localized faults detectable by conventional spectral analysis.
• This lack of effective diagnostic methods necessitates new approaches to prevent unexpected shutdowns and reduce maintenance costs.

Purpose of the Study:

• To develop and validate a reliable method for early fault diagnosis of bearing corrosion in induction motors.
• To explore the effectiveness of magnetic stray flux and vibration signal analysis for detecting diffuse corrosion.
• To enhance diagnostic accuracy and robustness using advanced signal processing and machine learning techniques.

Main Methods:

• Analysis of magnetic stray flux and vibration signals under varying levels of bearing corrosion.
• Utilizing statistical and non-statistical parameters to capture motor dynamic behavior changes.
• Employing genetic algorithms for feature selection and ensemble learning model optimization.
• Implementing a Support Vector Machine (SVM) with the bagging method for robust classification.

Main Results:

• The proposed approach successfully identified varying degrees of bearing corrosion.
• Achieved a classification accuracy exceeding 99% for distinguishing between healthy and corroded states.
• Demonstrated the reliability and efficiency of the combined magnetic stray flux, vibration analysis, and ensemble learning method.

Conclusions:

• The developed method provides a reliable and efficient solution for early fault diagnosis of bearing corrosion in induction motors.
• The integration of signal analysis, genetic algorithms, and ensemble learning significantly improves diagnostic accuracy.
• This approach offers a promising strategy to mitigate economic losses associated with induction motor failures due to bearing corrosion.