A smart anomaly detection system for industrial machines based on feature autoencoder and deep learning

Machine-health-surveillance systems are gaining popularity in industrial manufacturing systems due to the widespread availability of low-cost devices, sensors, and internet connectivity. In this regard, artificial intelligence provides valuable assistance in the form of deep learning methods to analyze and process big machine data. In diverse industrial applications, gears are considered a condemning element; many contributing failures occur due to an unexpected breakdown of the gears. In recent research, anomaly-detection and fault-diagnosis systems have been the gears’ most contributing content. Thus, in work, we presented a smart deep learning-based system to detect anomalies in an industrial machine. Our system used vibrational analysis methods as a deciding tool for different machinery-maintenance decisions. We will first perform a data analysis of the gearbox data set to analyze the data’s insights. By calculating and examining the machine’s vibration, we aim to determine the nature and severity of the defect in the machine and hence detect the anomaly. A gearbox’s vibration signal holds the fault’s signature in the gears, and earlier fault detection of the gearbox is achievable by examining the vibration signal using a deep learning technique. Therefore, we aim to propose a 6-layer autoencoder-based deep learning framework for anomaly detection and fault analysis using a publically available data set of wind-turbine components. The gearbox fault-diagnosis data set is utilized for experimentation, including collecting vibration attributes recorded using SpectraQuest’s gearbox fault-diagnostics simulator. Through comprehensive experiments, we have seen that the framework gains good results compared to others, with an overall accuracy of 91%.