基于多模态数据和UAViT的带式输送机托辊轴承故障诊断方法

Fault diagnosis method for belt conveyor idler bearings based on multimodal data and UAViT

  • 摘要: 针对现有带式输送机托辊轴承内圈裂纹和外圈磨损故障信息表征不显著、缺乏多模态信息有效融合利用机制且融合效果不稳定而导致故障诊断模型泛化能力差、故障辨识度低的问题,提出一种融合多模态数据和统一聚合视觉变换器(UAViT)的带式输送机托辊轴承故障诊断方法。首先,通过微机电系统(MEMS)光纤振动传感器和GSD5矿用本安型声传感器采集带式输送机托辊轴承运行过程中的原始振动信号和音频信号。其次,划分信号区间,通过小波阈值降噪、Wiener滤波及短时傅里叶变换处理原始信号,提取振动信号的时频图和音频信号的窄带语谱图,制作数据集。然后,构建包含聚合知识提取模块(AKEM)和隐式先验知识迁移模块(IPKTM)的UAViT模型,通过2个模块协同有效实现多模态信息的深度互补融合与稳定泛化诊断。最后,采用两阶段有监督学习策略对UAViT模型进行训练,并在测试集上输出托辊故障诊断结果。基于某矿区实际采集数据集开展实验,结果表明UAViT对内圈裂纹与外圈磨损故障的诊断准确率达99.67%;消融与控制变量实验证实了碎片交叉注意力机制(FCAM)、IPKTM及降噪方法的有效性;对比实验显示UAViT的故障诊断准确率较现有先进模型提升1.27%~6.67%;极端噪声、非典型故障泛化及跨设备迁移实验系统揭示了UAViT在强噪声、未知故障及设备差异场景下的性能边界。该方法在工程应用中成功诊断多起实际故障,验证了UAViT在煤矿井下复杂环境中的实用性与可靠性。

     

    Abstract: To address the problems that fault information of inner-ring cracks and outer-ring wear of belt conveyor idler bearings is not effectively represented, that effective fusion and utilization mechanisms for multimodal information are lacking, and that unstable fusion effects lead to poor generalization ability and low fault discrimination of diagnosis models, a fault diagnosis method for belt conveyor idler bearings integrating multimodal data and Unified Aggregation Visual Transformer (UAViT) was proposed. First, raw vibration signals and audio signals during the operation of belt conveyor idler bearings were collected by a Micro-Electro-Mechanical System (MEMS) optical fiber vibration sensor and a GSD5 intrinsically safe mining acoustic sensor. Second, signal intervals were segmented, and the raw signals were processed using wavelet threshold denoising, Wiener filtering, and short-time Fourier transform to extract time-frequency images of vibration signals and narrowband spectrograms of audio signals, thereby constructing a dataset. Then, a UAViT model containing an Aggregation Knowledge Extraction Module (AKEM) and an Implicit Prior Knowledge Transfer Module (IPKTM) was constructed, and the two modules jointly achieved deep complementary fusion and stable generalized diagnosis of multimodal information. Finally, the UAViT model was trained using a two-stage supervised learning strategy, and fault diagnosis results for the idlers were obtained on the test set. Experiments based on a real-world dataset collected from a mining area showed that the diagnostic accuracy of UAViT for inner-ring cracks and outer-ring wear faults reached 99.67%. Ablation and control-variable experiments verified the effectiveness of Feature Channel Attention Mechanism(FCAM), IPKTM and the denoising method. Comparative experiments showed that the fault diagnosis accuracy of UAViT was 1.27%-6.67% higher than that of existing advanced models. Extreme-noise, atypical-fault generalization, and cross-device transfer experiments systematically revealed the performance boundaries of UAViT under strong noise, unknown faults, and cross-device variation scenarios. The method successfully diagnoses multiple real-world faults in engineering applications, verifying the practicality and reliability of UAViT in the complex underground environment of coal mines.

     

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