Improving the Performance of Convolutional GAN Using History-State Ensemble for Unsupervised Early Fault Detection with Acoustic Emission Signals

Early fault detection (EFD) in run-to-failure processes plays a crucial role in the condition monitoring of modern industrial rotating facilities, which entail increasing demands for safety, energy and ecological savings and efficiency. To enable effective protection measures, the evolving faults have to be recognized and identified as early as possible. The major challenge is to distil discriminative features on the basis of only the ‘health’ signal, which is uniquely available from various possible sensors before damage sets in and before the signatures of incipient damage become obvious and well-understood in the signal. Acoustic emission (AE) signals have been frequently reported to be able to deliver early diagnostic information due to their inherently high sensitivity to the incipient fault activities, highlighting the great potential of the AE technique for EFD, which may outperform the traditional vibration-based analysis in many situations. To date, the ‘feature-based’ multivariate analysis dominates the interpretation of AE waveforms. In this way, the decision-making relies heavily on experts’ knowledge and experience, which is often a weak link in the entire EFD chain. With the advent of artificial intelligence, practitioners seek an intelligent method capable of tackling this challenge. In the present paper, we introduce a versatile approach towards intelligent data analysis adapted to AE signals streaming from the sensors used for the continuous monitoring of rotating machinery. A new architecture with a convolutional generative adversarial network (GAN) is designed to extract the deep information embedded in the AE waveforms. In order to improve the robustness of the proposed EFD framework, a novel ensemble technique referred to as ‘history-state ensemble’ (HSE) is introduced and paired with GAN. The primary merits of HSE are twofold: (1) it does not require extra computing time to obtain the base models, and (2) it does not require a special design of the network architecture and can be applied to different networks. To evaluate the proposed method, a durability rolling contact fatigue test was performed with the use of AE monitoring. The experimental results have demonstrated that the proposed ensemble method largely improves the robustness of GAN.