煤矿主通风机轴承抗愈合健康指标与并行剩余寿命预测模型

Anti-self-healing health indicator and parallel remaining useful life prediction model for coal mine main fan bearings

  • 摘要: 针对煤矿主通风机轴承退化过程中“愈合”现象导致健康指标(Health Indicator,HI)单调性下降,以及复杂工况下剩余寿命(Remaining Useful Life,RUL)预测精度不足的问题,提出一种抗“愈合”HI构建方法和一种多分支并行RUL预测模型。在抗“愈合”HI构建方法中,首先分析时域、频域和时频域特征对轴承退化过程的不同表征能力,提取能够反映振动能量、冲击强度、频谱结构和多尺度能量演化的多维特征;然后以轴承外圈、内圈、滚动体和保持架故障特征频率及其倍频附近的能量作为退化阶段划分依据,构建特征活动度曲线,并结合主成分分析、阶段自适应加权和近似保序平滑策略生成抗“愈合”HI,以降低“愈合”现象对退化表征的影响。在多分支并行RUL预测模型中,首先根据不同特征域信号的特点,分别利用时序卷积网络(Temporal Convolutional Network,TCN)与卷积注意力模块(Convolutional Block Attention Module,CBAM)结合的模型TCN−CBAM、谐波注意力增强的长短期记忆网络模型(Long Short Term Memory network,LSTM)和以能量分布与时频状态空间增强模块改进的视觉Transformer模型(Vision Transformer,ViT)对时域、频域及时频域特征进行针对性建模,并通过HI引导的动态融合机制实现多域退化预测信息融合。同时针对煤矿主通风机现场供电谐波、扇叶通过频率和润滑状态波动等非退化因素,设计物理信息约束,削弱外部工况扰动对RUL预测结果的影响。试验部分采用辛辛那提大学智能维护系统(Intelligent Maintenance Systems,IMS)轴承数据集、西安交通大学–昇阳科技(Xi’an Jiaotong University–Sumyoung Technology,XJTU−SY)轴承数据集和煤矿主通风机现场数据集进行效果验证。HI效果对比试验中,所构建HI在多个数据集上的趋势性和相关性均优于单一特征或由主成分分析(Principal Component Analysis,PCA)、去噪自编码器(Denoising Autoencoder,DAE)、变分自编码器(Variational Autoencoder,VAE)方法构建的健康指标,在IMS数据集中趋势性和相关性指标分别达到0.988和0.975,在现场数据集中分别达到0.919和0.948。RUL预测对比试验中,所提出的模型在现场数据集中平均绝对误差(Mean Absolute Error,MAE)、均方根误差(Root Mean Square Error,RMSE)和决定系数(R2)分别为2.16、2.98和0.964,优于LSTM、TCN、ViT、图注意力网络(Graph Attention Network,GAT)、Mamba和Diffusion等对比模型。最后通过消融试验,验证了HI引导机制和物理信息神经网络(Physics-Informed Neural Network,PINN)在预测模型中起到的作用。研究结果表明,所提方法能够提高HI对轴承真实退化趋势的表征能力,并提升复杂工况下煤矿主通风机轴承RUL预测的准确性和稳定性。

     

    Abstract: To address the reduced monotonicity of the Health Indicator (HI) caused by the “self-healing” phenomenon during the degradation of coal mine main fan bearings, as well as the insufficient accuracy of Remaining Useful Life (RUL) prediction under complex operating conditions, an anti-self-healing HI construction method and a multi-branch parallel RUL prediction model are proposed. For anti-self-healing HI construction, the different capabilities of time-domain, frequency-domain, and time-frequency-domain features in characterizing bearing degradation are first analyzed, and multidimensional features reflecting vibration energy, impact intensity, spectral structure, and multiscale energy evolution are extracted. The energies around the characteristic frequencies and their harmonics associated with outer-race, inner-race, rolling-element, and cage faults are then used to divide the degradation process into different stages. Feature activity curves are constructed, and an anti-self-healing HI is generated by combining Principal Component Analysis (PCA), stage-adaptive weighting, and approximate isotonic smoothing, thereby reducing the influence of the “self-healing” phenomenon on degradation characterization. For RUL prediction, the time-domain, frequency-domain, and time-frequency-domain features are modeled separately according to their respective characteristics using a Temporal Convolutional Network with a Convolutional Block Attention Module (TCN−CBAM), a harmonic-attention-enhanced Long Short Term Memory network (LSTM), and a Vision Transformer (ViT) enhanced with energy-distribution and time-frequency state-space modules. An HI-guided dynamic fusion mechanism is subsequently employed to integrate predictive degradation information from multiple feature domains. Meanwhile, Physics-Informed Neural Network (PINN) constraints are designed for disturbances unrelated to bearing degradation, including power-supply harmonics, blade-passing frequency components, and lubrication-state fluctuations, to mitigate the influence of external operating-condition disturbances on RUL prediction. The proposed methods are evaluated using the University of Cincinnati Intelligent Maintenance Systems (IMS) bearing dataset, Xi’an Jiaotong University–Sumyoung Technology (XJTU−SY) rolling bearing accelerated life test dataset, and a field dataset collected from a coal mine main fan. In the HI comparison experiments, the proposed HI outperforms individual features and the HIs constructed using PCA, a Denoising Autoencoder (DAE), and a Variational Autoencoder (VAE) in terms of monotonicity and correlation across multiple datasets. Specifically, its monotonicity and correlation reach 0.988 and 0.975, respectively, on the IMS dataset, and 0.919 and 0.948, respectively, on the field dataset. In the RUL prediction experiments, the proposed model achieves a Mean Absolute Error (MAE) of 2.16, a Root Mean Square Error (RMSE) of 2.98, and a coefficient of determination (R2) of 0.964 on the field dataset, outperforming LSTM, TCN, ViT, Graph Attention Network (GAT), Mamba, and diffusion-based models. Finally, ablation experiments verify the contributions of the HI-guided mechanism and the PINN constraints to the prediction model. The results demonstrate that the proposed methods improve the capability of the HI to characterize the actual degradation trend of bearings and enhance the accuracy and stability of RUL prediction for coal mine main fan bearings under complex operating conditions.

     

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