Improving the performance of univariate control charts for abnormal detection and classification

Abstract Bearing failures in rotating machinery can cause machine breakdown and economical loss, if no effective actions are taken on time. Therefore, it is of prime importance to detect accurately the presence of faults, especially at their early stage, to prevent sequent damage and reduce costly downtime. The machinery fault diagnosis follows a roadmap of data acquisition, feature extraction and diagnostic decision making, in which mechanical vibration fault feature extraction is the foundation and the key to obtain an accurate diagnostic result. A challenge in this area is the selection of the most sensitive features for various types of fault, especially when the characteristics of failures are difficult to be extracted. Thus, a plethora of complex data-driven fault diagnosis methods are fed by prominent features, which are extracted and reduced through traditional or modern algorithms. Since most of the available datasets are captured during normal operating conditions, the last decade a number of novelty detection methods, able to work when only normal data are available, have been developed. In this study, a hybrid method combining univariate control charts and a feature extraction scheme is introduced focusing towards an abnormal change detection and classification, under the assumption that measurements under normal operating conditions of the machinery are available. The feature extraction method integrates the morphological operators and the Morlet wavelets. The effectiveness of the proposed methodology is validated on two different experimental cases with bearing faults, demonstrating that the proposed approach can improve the fault detection and classification performance of conventional control charts.