CN116070083A - An Intelligent Identification Algorithm for Wire Rope Faults Based on Convolutional Neural Network - Google Patents
An Intelligent Identification Algorithm for Wire Rope Faults Based on Convolutional Neural Network Download PDFInfo
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Abstract
本发明公开了一种基于卷积神经网络的钢丝绳故障智能识别方法和系统,属于机械故障诊断领域,该方法包括:首先进行故障数据采集,通过传感器采集不同种类的原始一维漏磁信号;将损伤原始一维漏磁信号通过连续小波变换转换成二维时频图像,以保留信号的时域信息和频域信息;将二维时频图像划分为70%的训练集和30%的验证集;本发明构建了一个卷积神经网络模型,设置好相关的模型结构和参数后,加载训练集进行模型训练,在训练过程中不断调整模型结构以得到最优的卷积神经网络模型;最后将训练好的模型用于钢丝绳故障的诊断和识别,系统生成故障类别和识别的概率。该方法可用于识别多种钢丝绳内外部损伤,减少传统识别方法中的人工参与,并能提升故障识别的准确率。
The invention discloses a method and system for intelligent identification of steel wire rope faults based on a convolutional neural network, belonging to the field of mechanical fault diagnosis. The method includes: first collecting fault data, and collecting different types of original one-dimensional magnetic flux leakage signals through sensors; The damaged original one-dimensional magnetic flux leakage signal is transformed into two-dimensional time-frequency image by continuous wavelet transform to preserve the time-domain information and frequency-domain information of the signal; the two-dimensional time-frequency image is divided into 70% training set and 30% validation set The present invention builds a convolutional neural network model, after setting relevant model structures and parameters, loads the training set to carry out model training, constantly adjusts the model structure in the training process to obtain the optimal convolutional neural network model; finally The trained model is used to diagnose and identify wire rope faults, and the system generates fault categories and identification probabilities. This method can be used to identify various internal and external damages of steel wire ropes, reduce manual participation in traditional identification methods, and improve the accuracy of fault identification.
Description
技术领域Technical Field
本发明涉及故障诊断技术领域,确切地说是一种基于卷积神经网络的钢丝绳故障智能识别算法。The invention relates to the technical field of fault diagnosis, and more specifically to an intelligent recognition algorithm for wire rope faults based on a convolutional neural network.
背景技术Background Art
钢丝绳在许多工作场景中常作为主要的承力部件,如矿井索道运载、斜张桥、电梯运行等。恶劣的工作环境难免会导致钢丝绳产生各类损伤,直接关系到钢丝绳的使用安全。现如今,各行业对钢丝绳的需求量逐渐增大,各部门也更加重视钢丝绳的使用安全。准确评价钢丝绳的服役状态不仅能保证生产的安全性,而且能减少钢丝绳的用量成本,提高企业效益。目前钢丝绳故障诊断需要具备一定专业知识的人工参与且准确率不高,致使许多企业仍使用人工检查和定期换绳的方法保障钢丝绳使用安全。然而,人工检查受工作人员状态影响且难以检测内部损伤,定期更换又会造成巨大浪费。因此,研究高准确率、高可靠性且能够识别内部损伤的钢丝绳故障智能诊断方法具有重要意义。Wire ropes are often used as the main load-bearing components in many work scenarios, such as mine ropeway transportation, cable-stayed bridges, elevator operations, etc. Harsh working environments will inevitably cause various types of damage to wire ropes, which is directly related to the safety of wire rope use. Nowadays, the demand for wire ropes in various industries is gradually increasing, and various departments are also paying more attention to the safety of wire rope use. Accurately evaluating the service status of wire ropes can not only ensure the safety of production, but also reduce the cost of wire rope usage and improve corporate benefits. At present, wire rope fault diagnosis requires manual participation with certain professional knowledge and the accuracy is not high, causing many companies to still use manual inspection and regular rope replacement methods to ensure the safety of wire rope use. However, manual inspection is affected by the status of the staff and it is difficult to detect internal damage, and regular replacement will cause huge waste. Therefore, it is of great significance to study an intelligent wire rope fault diagnosis method with high accuracy, high reliability and the ability to identify internal damage.
公布号为CN 109019210 A的中国专利,公开了一种基于卷积神经网络的提升系统尾绳健康监测系统及方法,其技术内容为:图像采集系统用于采集尾绳状态,将尾绳状态通过移动无线传感器网络传输至上位机,由上位机对图像数据进行深度挖掘,并针对尾绳状态进行故障分析与预警。其存在的技术问题是图像采集系统所采集的钢丝绳损伤特征仅限于钢丝绳表面损伤特征,不能采集钢丝绳深层损伤特征,故钢丝绳内部损伤特征无法检测;图像采集系统仅能采集相机正面所对钢丝绳的表面损伤特征,故不能检测钢丝绳另一面的钢丝绳损伤特征;图像采集系统受所处光源及环境影响大,故采集钢丝绳表面损伤特征稳定性差,不能保证图像采集的一致性;The Chinese patent with publication number CN 109019210 A discloses a tail rope health monitoring system and method for a hoisting system based on a convolutional neural network. Its technical content is: the image acquisition system is used to acquire the status of the tail rope, and transmit the status of the tail rope to the host computer through a mobile wireless sensor network. The host computer conducts in-depth mining of the image data, and performs fault analysis and early warning for the status of the tail rope. The technical problem is that the damage characteristics of the wire rope acquired by the image acquisition system are limited to the surface damage characteristics of the wire rope, and the deep damage characteristics of the wire rope cannot be acquired, so the internal damage characteristics of the wire rope cannot be detected; the image acquisition system can only acquire the surface damage characteristics of the wire rope facing the front of the camera, so it cannot detect the damage characteristics of the wire rope on the other side of the wire rope; the image acquisition system is greatly affected by the light source and environment, so the stability of acquiring the surface damage characteristics of the wire rope is poor, and the consistency of image acquisition cannot be guaranteed;
公布号为CN 114275483 A的中国专利,公开了一种带式输送机的智能在线监测系统,其技术内容为:传感器采集输送带的图像,同时采集各目标装置的温度数据与振动数据;弱磁无损检测用于检测输送带的带内钢丝绳内芯的损伤情况;边缘智能终端用于分析图像、温度数据以及振动数据并上传云端服务器;在云端服务器通过CNN卷积神经网络模型融合分析各项数据,得到带式输送机的健康状态。其存在的技术问题是:在此专利中,采集的钢丝绳内芯异常信息需经人工进行降噪预处理,其所用传统的钢丝绳内芯异常信息处理方法需要大量的专业经验且需要人工参与,具有一定局限性,不利于其系统的泛化性;此外,未指明所采集的钢丝绳内芯异常信息的图像转换过程。The Chinese patent with publication number CN 114275483 A discloses an intelligent online monitoring system for belt conveyors. Its technical content is: the sensor collects images of the conveyor belt and collects temperature data and vibration data of each target device at the same time; weak magnetic nondestructive testing is used to detect the damage of the inner core of the steel wire rope in the conveyor belt; the edge intelligent terminal is used to analyze the image, temperature data and vibration data and upload them to the cloud server; the cloud server uses the CNN convolutional neural network model to fuse and analyze various data to obtain the health status of the belt conveyor. The technical problems it has are: in this patent, the collected abnormal information of the steel wire rope inner core needs to be pre-processed by manual noise reduction. The traditional method of processing abnormal information of the steel wire rope inner core requires a lot of professional experience and manual participation, which has certain limitations and is not conducive to the generalization of its system; in addition, the image conversion process of the collected abnormal information of the steel wire rope inner core is not specified.
因此,本发明基于连续小波变换和卷积神经网络提出一种能够智能识别钢丝绳内外部损伤的故障诊断方法。该方法对于钢丝绳故障诊断中需要人工参与、精度不高以及内外部损伤问题的解决具有重要意义。Therefore, the present invention proposes a fault diagnosis method based on continuous wavelet transform and convolutional neural network that can intelligently identify internal and external damage of wire ropes. This method is of great significance for solving the problems of wire rope fault diagnosis that require manual participation, low accuracy, and internal and external damage.
发明内容Summary of the invention
本发明要解决的技术问题是提供一种基于卷积神经网络的钢丝绳故障智能识别算法,该算法能够解决传统识别方法需要人工参与和准确率不高的问题。The technical problem to be solved by the present invention is to provide an intelligent wire rope fault recognition algorithm based on convolutional neural network, which can solve the problems that traditional recognition methods require manual participation and have low accuracy.
为解决上述技术问题,本发明采用如下技术手段:In order to solve the above technical problems, the present invention adopts the following technical means:
一种基于卷积神经网络的钢丝绳故障智能识别算法,包括以下步骤:An intelligent wire rope fault identification algorithm based on convolutional neural network includes the following steps:
(1)信号采集:通过钢丝绳损伤检测传感器采集不同钢丝绳损伤试件的原始一维漏磁信号;(1) Signal acquisition: The original one-dimensional magnetic flux leakage signal of different wire rope damage specimens is collected through the wire rope damage detection sensor;
(2)信号预处理:得到损伤原始一维漏磁信号后,将每一处的漏磁信号从原始信号中切割出来,利用连续小波变换对原始漏磁信号进行时频分析,生成相应的二维时频图像;(2) Signal preprocessing: After obtaining the original one-dimensional magnetic leakage signal of the damage, the magnetic leakage signal of each location is cut out from the original signal, and the original magnetic leakage signal is analyzed in time and frequency using continuous wavelet transform to generate the corresponding two-dimensional time and frequency image;
(3)卷积神经网络训练学习划分为训练集和验证集:本发明将步骤(2)中生成的二维时频图像划分为:训练集70%,验证集30%;(3) The convolutional neural network training and learning is divided into a training set and a validation set: the present invention divides the two-dimensional time-frequency image generated in step (2) into: a training set of 70% and a validation set of 30%;
(4)构建卷积神经网络模型:卷积神经网络模型的基本结构为卷积层、池化层、全连接层和SoftMax层。通过卷积神经网络输入的二维时频图像进行训练和分类,模型参数全部随机初始化,通过训练集不断调整模型结构和参数来减小预测标签和实际标签之间的误差,最终确定模型的参数,完成钢丝绳故障智能识别模型的搭建;(4) Constructing a convolutional neural network model: The basic structure of the convolutional neural network model is a convolutional layer, a pooling layer, a fully connected layer, and a SoftMax layer. The convolutional neural network is trained and classified using a two-dimensional time-frequency image input. All model parameters are randomly initialized. The model structure and parameters are continuously adjusted through the training set to reduce the error between the predicted label and the actual label. Finally, the model parameters are determined to complete the construction of the wire rope fault intelligent identification model.
(5)将训练好的卷积神经网络模型用于钢丝绳故障识别系统中,输入钢丝绳损伤检测传感器采集的信号,通过步骤(4)的卷积神经网络模型进行处理。(5) The trained convolutional neural network model is used in the wire rope fault identification system, and the signal collected by the wire rope damage detection sensor is input and processed by the convolutional neural network model of step (4).
作为对本技术方案的进一步改进:As a further improvement to this technical solution:
所述的步骤(2)中,原始一维漏磁信号被转换成二维时频图像,以保留信号的时域信息和频域信息,被转换的信号x(t)的连续小波变换可以表示为:In the step (2), the original one-dimensional magnetic flux leakage signal is converted into a two-dimensional time-frequency image to retain the time domain information and frequency domain information of the signal. The continuous wavelet transform of the converted signal x(t) can be expressed as:
式中,x(t)表示被转换的信号;ψ(t)为母小波,ψ*(t)为函数ψ(t)的复共轭;a为尺度因子,b为平移因子;通过小波变换后,一维信号x(t)被分解成一系列与尺度因子a和平移因子b相关的小波系数,从而转换成二维时频图像。In the formula, x(t) represents the converted signal; ψ(t) is the mother wavelet, ψ * (t) is the complex conjugate of the function ψ(t); a is the scale factor, and b is the translation factor; after wavelet transform, the one-dimensional signal x(t) is decomposed into a series of wavelet coefficients related to the scale factor a and the translation factor b, and then converted into a two-dimensional time-frequency image.
所述的步骤(2)中卷积神经网络输入二维时频图像的图像分辨率为224*224的3通道图像,批次为21,初始学习率为0.0001,优化函数使用adam,训练轮数为12,激活函数为ReLU。In the step (2), the image resolution of the convolutional neural network input two-dimensional time-frequency image is a 3-channel image of 224*224, the batch size is 21, the initial learning rate is 0.0001, the optimization function uses adam, the number of training rounds is 12, and the activation function is ReLU.
所述的步骤(3)中,由步骤(2)已生成的二维时频图像,将生成的所有二维时频图像划分为70%和30%。70%的二维时频图像是用于卷积神经网络训练学习以形成可用的特征信息,即70%的数据作为训练集。已形成可用的特征信息以识别剩下30%的二维时频图像,即30%的数据作为验证集。In the step (3), all the two-dimensional time-frequency images generated by the step (2) are divided into 70% and 30%. 70% of the two-dimensional time-frequency images are used for convolutional neural network training and learning to form usable feature information, that is, 70% of the data is used as a training set. The remaining 30% of the two-dimensional time-frequency images, that is, 30% of the data, which have formed usable feature information to identify, are used as a verification set.
所述的步骤(4)中,同一个卷积层中的神经元可共享其权重,多个权重可形成一个卷积核;卷积层具有多个卷积核可同时提取不同的特征信息;卷积核对输入图像进行卷积运算,基于非线性激活函数得出最终输出值;卷积层以推导网络中的反向传播更新为前进方向并在其下面各层的特征图上的卷积核组成特征图,即卷积核扫描整个输入图像生成特征图,卷积核可以看作是一种特征提取器,不同的卷积核表示不同的特征提取操作;非线性变换前的第k个特征图的特征值Zk可以表示为:In the step (4), neurons in the same convolution layer can share their weights, and multiple weights can form a convolution kernel; the convolution layer has multiple convolution kernels that can simultaneously extract different feature information; the convolution kernel performs a convolution operation on the input image and obtains a final output value based on a nonlinear activation function; the convolution layer uses the back propagation in the derivation network to update the forward direction and the convolution kernels on the feature maps of the layers below it form a feature map, that is, the convolution kernel scans the entire input image to generate a feature map, and the convolution kernel can be regarded as a feature extractor, and different convolution kernels represent different feature extraction operations; the feature value Z k of the kth feature map before the nonlinear transformation can be expressed as:
式中,Wk表示第k个卷积核,bk表示偏移项,x是此卷积层的输入图像,表示二维卷积。Where Wk represents the kth convolution kernel, bk represents the offset term, x is the input image of this convolution layer, Represents a two-dimensional convolution.
池化层一般在卷积层之后,通过下采样方式来对卷积生成的特征图进行降维处理,并且池化层可将特征图分为多个小区域以生成新的特征值向量,可以表示为:The pooling layer is usually placed after the convolution layer. It reduces the dimension of the feature map generated by the convolution by downsampling. The pooling layer can divide the feature map into multiple small areas to generate a new eigenvalue vector, which can be expressed as:
式中,down(·)是下采样函数;yi,j,k表示池化后第k个新特征图;Ri,j是位置(i,j)附近的区域,即池化的感受野;xm,n,k表示感受野内的节点;本算法中使用的池化函数为最大值池化函数,即在池化域内选取最大值作为新特征值。Where down(·) is the downsampling function; yi ,j,k represents the kth new feature map after pooling; Ri ,j is the area near the position (i,j), that is, the receptive field of the pooling; xm,n,k represents the node in the receptive field; the pooling function used in this algorithm is the maximum pooling function, that is, the maximum value in the pooling domain is selected as the new feature value.
经卷积层和池化层之后为全连接层和SoftMax层,其作用为对已完成卷积层和池化层产生的结果进行分类或逻辑回归;全连接层可应用于多种分类模型,以便划分T个类别,全连接层的神经元个数设置为T,输出层将其下一层的并发特征图作为输入,用fv表示特征向量,则有:After the convolution layer and the pooling layer, there is a fully connected layer and a SoftMax layer, which is used to classify or logistically regress the results of the completed convolution layer and the pooling layer; the fully connected layer can be applied to a variety of classification models to divide T categories. The number of neurons in the fully connected layer is set to T. The output layer takes the concurrent feature map of the next layer as input, and uses f v to represent the feature vector, then:
O=f(bo+wofv) (4)O=f( bo + wofv ) (4)
式中,bo是偏置向量,wo表示权重矩阵。Where b o is the bias vector and w o represents the weight matrix.
卷积神经网络训练学习是基于梯度下降来完成的,卷积神经网络模型中bo和wo均为可学习参数,而梯度下降可用反向传播算法的卷积方式,从而使卷积神经网络自己不断训练学习,对于大批量的数据处理,底层优化算法的计算复杂度大大增加,而随机梯度下降法在分析大批量数据上具有高效率的优点,利用梯度下降可以使经验风险En(fw)最小化,每次迭代都根据En(fw)的梯度更新权重w,有:Convolutional neural network training and learning is based on gradient descent. Both b o and w o are learnable parameters, and gradient descent can use the convolution method of the back-propagation algorithm, so that the convolutional neural network can continuously train and learn. For large-scale data processing, the computational complexity of the underlying optimization algorithm is greatly increased, and the stochastic gradient descent method has the advantage of high efficiency in analyzing large-scale data. The empirical risk En (f w ) can be minimized by using gradient descent. Each iteration updates the weight w according to the gradient of En (f w ), as follows:
式中,γ表示增益,其值可根据具体情况选择合适的值。在充分正则性假设下,当初始估计w0足够接近最优时,且当增益γ足够小时,该算法达到线性收敛。Where γ represents the gain, and its value can be selected appropriately according to the specific situation. Under the assumption of sufficient regularity, when the initial estimate w0 is close enough to the optimal value and when the gain γ is small enough, the algorithm reaches linear convergence.
通过将标量增益γ替换为正定矩阵Γt可以设计出更好的优化算法,该矩阵在最优时逼近海森矩阵(Hessian)的逆矩阵:A better optimization algorithm can be designed by replacing the scalar gain γ with a positive definite matrix Γ t , which approximates the inverse of the Hessian matrix at the optimal point:
二阶梯度下降是众所周知的牛顿算法(Newton Algorithm),在充分乐观的正则性假设下,在w0足够接近最优的情况下,二阶梯度下降达到二次收敛。Second-order gradient descent is a well-known Newton algorithm. Under a sufficiently optimistic regularity assumption, when w 0 is close enough to the optimal, second-order gradient descent reaches quadratic convergence.
采用上述技术方案的本发明,与现有技术相比,其突出的特点是:Compared with the prior art, the present invention adopting the above technical solution has the following outstanding features:
(1)信号预处理的过程优化(1) Optimization of signal preprocessing process
传统方法需要人工对信号进行去噪等预处理,需要具备专业经验并耗费大量的精力,本发明引入连续小波变换将钢丝绳断丝损伤一维原始信号转换成二维时频图像,保留信号时频信息,优化了信号预处理过程。Traditional methods require manual preprocessing of signals such as denoising, which requires professional experience and consumes a lot of energy. The present invention introduces continuous wavelet transform to convert the one-dimensional original signal of wire rope broken wire damage into a two-dimensional time-frequency image, retaining the signal time-frequency information and optimizing the signal preprocessing process.
(2)基于CNN的自适应特征提取方法(2) Adaptive feature extraction method based on CNN
传统的故障识别由人工进行特征提取,信息提取不彻底,分类准确率低。以及目前所提出的识别模型主要为BP神经网络及其改进网络、支持向量机、超限学习机等浅层网络模型,这些识别模型的学习能力有限,对钢丝绳损伤的识别效果依赖于人工提取的特征。本发明提出一种基于卷积神经网络的自适应特征提取方法,挖掘钢丝绳损伤信号中的深层特征。通过卷积神经网络模型从损伤二维时频图像中自动提取特征,并逐步融合、优化形成有利于分类的抽象特征,突破了传统的人工特征提取方法的局限性,为钢丝绳损伤识别提供了区分度更高的特征。Traditional fault identification is based on manual feature extraction, which results in incomplete information extraction and low classification accuracy. The currently proposed recognition models are mainly shallow network models such as BP neural network and its improved network, support vector machine, and extreme learning machine. The learning ability of these recognition models is limited, and the recognition effect of wire rope damage depends on manually extracted features. The present invention proposes an adaptive feature extraction method based on convolutional neural network to mine deep features in wire rope damage signals. The convolutional neural network model is used to automatically extract features from the two-dimensional time-frequency image of the damage, and gradually fuses and optimizes them to form abstract features that are conducive to classification. This breaks through the limitations of traditional manual feature extraction methods and provides more discriminative features for wire rope damage identification.
(3)基于CNN的钢丝绳故障智能识别系统(3) Wire rope fault intelligent identification system based on CNN
针对目前已有断丝定量识别模型准确率和泛化性不高的问题,提出了基于卷积神经网络的钢丝绳断丝损伤定量识别方法。将断丝损伤漏磁信号转换成的二维时频图像作为卷积神经网络的输入,并对不同结构参数的卷积神经网络进行测试,建立了最优的卷积神经网络识别模型,实现了不同钢丝绳损伤的高精度识别。Aiming at the low accuracy and generalization of the existing broken wire quantitative identification model, a quantitative identification method for broken wire damage in wire rope based on convolutional neural network is proposed. The two-dimensional time-frequency image converted from the leakage magnetic signal of broken wire damage is used as the input of convolutional neural network, and the convolutional neural network with different structural parameters is tested. The optimal convolutional neural network recognition model is established, and high-precision identification of different wire rope damage is achieved.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1是卷积神经网络的典型结构。Figure 1 is the typical structure of a convolutional neural network.
图2是本发明的整体流程图。FIG. 2 is an overall flow chart of the present invention.
图3是基于卷积神经网络的钢丝绳故障智能识别系统。Figure 3 is an intelligent wire rope fault identification system based on convolutional neural network.
图4是钢丝绳断丝位置,其中图4a是钢丝绳外部断丝位置,分别为外部1根、2根、3根、4根、5根断丝;图4b是钢丝绳内部断丝位置,分别为1根、2根、3根断丝。Figure 4 shows the locations of broken wires in the wire rope, wherein Figure 4a shows the locations of broken wires outside the wire rope, which are 1, 2, 3, 4 and 5 broken wires respectively; Figure 4b shows the locations of broken wires inside the wire rope, which are 1, 2 and 3 broken wires respectively.
图5是信号采集流程图。FIG5 is a flow chart of signal acquisition.
图6是直径24mm钢丝绳各类断丝二维时频图像。Figure 6 is a two-dimensional time-frequency image of various types of broken wires in a 24mm diameter steel wire rope.
图7是选定模型对直径24mm钢丝绳各类断丝分类结果。Figure 7 shows the classification results of various types of broken wires in a 24mm diameter wire rope using the selected model.
图8是卷积神经网络自适应提取特征可视化结果。Figure 8 is the visualization result of the adaptive feature extraction of the convolutional neural network.
图9是直径24mmCNN网络断丝分类混淆矩阵。Figure 9 is the confusion matrix of broken wire classification of 24mm diameter CNN network.
图10是直径24mmBP网络断丝分类混淆矩阵。Figure 10 is the confusion matrix for the classification of broken wires in the BP network with a diameter of 24 mm.
具体实施方式DETAILED DESCRIPTION
时频成像是将信号频率、时间序列数据转换成二维时频图像的一种技术。通过时频转换可以洞察原始信号更深的特征,有利于进行故障分类。小波变换是故障诊断领域中一种常用的信号处理方法,这种方法非常适用于钢丝绳损伤产生的漏磁突变信号的处理。对一维信号进行时频转换的方法很多,其中小波变换非常适用于钢丝绳损伤产生的漏磁突变信号的处理。因此连续小波变换是一种将钢丝绳损伤一维信号转换到二维时频图的有效方法。深度学习自提出就受到了各个领域的关注,其中卷积神经网络已经在故障诊断领域取得了很多成功的应用。卷积神经网络模型作为一种深度学习模型,典型结构如图1所示,其用于图像特征分类效果显著。该网络可自动提取输入图像的特征信息,经网络多级处理后,去除了冗余的特征信息并在更高层形成了易分类的抽象特征,从而对图像类别的高精准分类。Time-frequency imaging is a technique that converts signal frequency and time series data into two-dimensional time-frequency images. Time-frequency conversion can provide insight into deeper features of the original signal, which is conducive to fault classification. Wavelet transform is a commonly used signal processing method in the field of fault diagnosis. This method is very suitable for processing leakage magnetic mutation signals caused by wire rope damage. There are many methods for time-frequency conversion of one-dimensional signals, among which wavelet transform is very suitable for processing leakage magnetic mutation signals caused by wire rope damage. Therefore, continuous wavelet transform is an effective method for converting one-dimensional signals of wire rope damage into two-dimensional time-frequency images. Since its proposal, deep learning has attracted attention from various fields, among which convolutional neural networks have achieved many successful applications in the field of fault diagnosis. As a deep learning model, the convolutional neural network model has a typical structure shown in Figure 1, and its effect on image feature classification is remarkable. The network can automatically extract the feature information of the input image. After multi-level network processing, redundant feature information is removed and abstract features that are easy to classify are formed at a higher level, thereby achieving high-precision classification of image categories.
如图2所示为本发明的整体流程。FIG. 2 shows the overall process of the present invention.
如图3所示基于卷积神经网络的钢丝绳故障智能识别系统,以直径为24mm钢丝绳为例,本实施例的一种基于卷积神经网络的钢丝绳故障智能识别算法:(1)信号采集:通过钢丝绳损伤检测传感器采集不同钢丝绳损伤试件的原始一维漏磁信号;(2)信号预处理:得到损伤原始一维漏磁信号后,将每一处的漏磁信号从原始信号中切割出来,利用连续小波变换对原始漏磁信号进行时频分析,生成相应的二维时频图像;(3)卷积神经网络训练学习划分为训练集和验证集:本发明将步骤(2)中生成的二维时频图像划分为:训练集70%,验证集30%;(4)构建卷积神经网络模型:卷积神经网络模型的基本结构为卷积层、池化层、全连接层和SoftMax层。通过卷积神经网络输入的二维时频图像进行训练和分类,模型参数全部随机初始化,通过训练集不断调整模型结构和参数来减小预测标签和实际标签之间的误差,最终确定模型的参数,完成钢丝绳故障智能识别模型的搭建;(5)将训练好的卷积神经网络模型用于钢丝绳故障识别系统中,输入钢丝绳损伤检测传感器采集的信号,通过步骤(4)的卷积神经网络模型进行处理。包括如下步骤:As shown in FIG3 , a wire rope fault intelligent identification system based on a convolutional neural network is shown. Taking a wire rope with a diameter of 24 mm as an example, an intelligent wire rope fault identification algorithm based on a convolutional neural network in this embodiment is as follows: (1) Signal acquisition: The original one-dimensional magnetic leakage signal of different wire rope damaged specimens is collected by a wire rope damage detection sensor; (2) Signal preprocessing: After obtaining the original one-dimensional magnetic leakage signal of the damage, the magnetic leakage signal of each location is cut out from the original signal, and the original magnetic leakage signal is subjected to time-frequency analysis using continuous wavelet transform to generate a corresponding two-dimensional time-frequency image; (3) Convolutional neural network training and learning are divided into a training set and a validation set: The present invention divides the two-dimensional time-frequency image generated in step (2) into: 70% for the training set and 30% for the validation set; (4) Convolutional neural network model is constructed: The basic structure of the convolutional neural network model is a convolution layer, a pooling layer, a fully connected layer and a SoftMax layer. The two-dimensional time-frequency image input by the convolutional neural network is trained and classified. All model parameters are randomly initialized. The model structure and parameters are continuously adjusted through the training set to reduce the error between the predicted label and the actual label. Finally, the parameters of the model are determined to complete the construction of the intelligent recognition model of wire rope faults; (5) The trained convolutional neural network model is used in the wire rope fault recognition system, and the signal collected by the wire rope damage detection sensor is input and processed by the convolutional neural network model of step (4). It includes the following steps:
步骤1:信号采集工作:通过钢丝绳损伤检测传感器采集不同钢丝绳损伤试件的原始一维漏磁信号。本发明主要研究对象为直径24mm钢丝绳的故障智能识别,为了保证实验数据采集情况的多元性和丰富性,设置5处外部断丝和3处内部断丝进行实验验证其发明原理合理性,断丝具体位置如图4所示。信号采集流程如图5所示,主要通过传感器采集8类内外部断丝的原始一维漏磁信号,其中每处断丝信号采集100个样本,8种断丝信号共为800个样本,并对各类钢丝绳故障情况进行了标签命名,8类标签的故障描述如表1.0所示。Step 1: Signal acquisition: The original one-dimensional magnetic leakage signals of different wire rope damage specimens are collected through the wire rope damage detection sensor. The main research object of the present invention is the intelligent fault identification of 24mm diameter wire rope. In order to ensure the diversity and richness of the experimental data collection, 5 external broken wires and 3 internal broken wires are set to experimentally verify the rationality of the invention principle. The specific position of the broken wire is shown in Figure 4. The signal acquisition process is shown in Figure 5. The original one-dimensional magnetic leakage signals of 8 types of internal and external broken wires are mainly collected by sensors, where 100 samples are collected for each broken wire signal, and 8 types of broken wire signals are 800 samples in total. Labels are named for various wire rope faults, and the fault descriptions of 8 types of labels are shown in Table 1.0.
表1.0.故障标签命名Table 1.0. Fault label naming
步骤2:信号预处理工作:得到损伤原始一维漏磁信号后,将每一处的漏磁信号从原始信号中切割出来,利用连续小波变换对原始漏磁信号进行时频分析,生成相应的二维时频图像。为了对直径24mm钢丝绳原始一维漏磁信号的特征进行高精确率提取,通过已采集的800个原始损伤信号样本,从原始一维漏磁信号中将每处断丝的漏磁信号分离出来,以分离出的漏磁信号作为新样本使用,将每处断丝的漏磁信号分割成多个数据块,其中每个数据块含1024个数据点,跳过人工对信号去噪预处理的传统方法,基于连续小波变换的方法将每个数据块转换成二维时频图像以作为卷积神经网络输入。连续小波变换的优点在于既能保留信号的时域信息又能保留其频域信息,并且不会丢失原始信号的特征信息。为充分发挥卷积神经网络模型对二维时频图像特征的提取能力,采集到的实验数据为原始一维漏磁信号,采用时频分析技术将原始一维漏磁信号转换成二维时频图像。Step 2: Signal preprocessing: After obtaining the original one-dimensional leakage magnetic flux signal of the damage, the leakage magnetic flux signal of each location is cut out from the original signal, and the original leakage magnetic flux signal is analyzed in time and frequency using continuous wavelet transform to generate the corresponding two-dimensional time-frequency image. In order to extract the features of the original one-dimensional leakage magnetic flux signal of the 24mm diameter steel wire rope with high accuracy, the leakage magnetic flux signal of each broken wire is separated from the original one-dimensional leakage magnetic flux signal through the 800 original damage signal samples collected, and the separated leakage magnetic flux signal is used as a new sample. The leakage magnetic flux signal of each broken wire is divided into multiple data blocks, each of which contains 1024 data points, skipping the traditional method of artificial signal denoising preprocessing, and converting each data block into a two-dimensional time-frequency image based on the continuous wavelet transform method as the input of the convolutional neural network. The advantage of continuous wavelet transform is that it can retain both the time domain information and the frequency domain information of the signal, and will not lose the characteristic information of the original signal. In order to give full play to the ability of the convolutional neural network model to extract the features of two-dimensional time-frequency images, the experimental data collected are the original one-dimensional magnetic leakage signal, and the time-frequency analysis technology is used to convert the original one-dimensional magnetic leakage signal into a two-dimensional time-frequency image.
步骤3:划分训练集、验证集:卷积神经网络训练学习划分为训练集和验证集:本发明将步骤(2)中生成的二维时频图像划分为:训练集70%,验证集30%。本发明将原始损伤信号样本分为两部分:训练集和验证集。其中划分的训练集在模型训练过程中使用,每一个epoch都会输出一个训练集准确率和损失率,以便于根据训练模型的准确率和损失率进行适当调整模型的结构和参数,从而逐渐提高模型深层特征提取的能力。验证集用于对训练集已训练好的模型进行全面评估,且同样也会输出验证集准确率和损失率,根据验证集结果来评估训练模型结构和参数的合理性。本发明将训练集和验证集分别按照70%、30%的比例进行划分。Step 3: Divide the training set and the validation set: The convolutional neural network training and learning is divided into a training set and a validation set: The present invention divides the two-dimensional time-frequency image generated in step (2) into: 70% for the training set and 30% for the validation set. The present invention divides the original damaged signal sample into two parts: a training set and a validation set. The divided training set is used in the model training process, and each epoch will output a training set accuracy and loss rate, so as to appropriately adjust the structure and parameters of the model according to the accuracy and loss rate of the training model, thereby gradually improving the model's ability to extract deep features. The validation set is used to comprehensively evaluate the model that has been trained in the training set, and will also output the validation set accuracy and loss rate, and evaluate the rationality of the training model structure and parameters based on the validation set results. The present invention divides the training set and the validation set into a ratio of 70% and 30% respectively.
步骤4:构建卷积神经网络模型:卷积神经网络模型的基本结构为卷积层、池化层、全连接层和SoftMax层。通过卷积神经网络输入的二维时频图像进行训练和分类,模型参数全部随机初始化,通过训练集不断调整模型结构和参数来减小预测标签和实际标签之间的误差,最终确定模型的参数,完成钢丝绳故障智能识别模型的搭建。使用MATLAB语言,以Simulink库搭建一种基于CNN的深度学习训练模型,卷积神经网络模型主要结构为:卷积层、池化层、全连接层和SoftMax层,以划分的训练集和验证集二维时频图像作为卷积神经网络的输入进行训练和分类,模型参数全部随机初始化。Step 4: Construct a convolutional neural network model: The basic structure of the convolutional neural network model is a convolutional layer, a pooling layer, a fully connected layer, and a SoftMax layer. The two-dimensional time-frequency image input by the convolutional neural network is used for training and classification. All model parameters are randomly initialized. The model structure and parameters are continuously adjusted through the training set to reduce the error between the predicted label and the actual label. Finally, the parameters of the model are determined to complete the construction of the intelligent recognition model of wire rope faults. Using MATLAB language and Simulink library, a deep learning training model based on CNN is built. The main structure of the convolutional neural network model is: convolutional layer, pooling layer, fully connected layer, and SoftMax layer. The divided two-dimensional time-frequency images of the training set and the validation set are used as the input of the convolutional neural network for training and classification. All model parameters are randomly initialized.
具体来说,所述卷积神经网络输入二维时频图像的图像分辨率为224*224的3通道图像,批次为21,初始学习率设置为0.0001,优化函数使用adam,训练轮数为12,激活函数为ReLU。因为二维卷积神经网络输入的RGB图像对尺寸有一定的要求,所以需对连续小波变换所转换的二维时频图像进行图像预处理。由于其特征为单通道的灰度图像,因此要把灰度图像复制到3个通道中且在每个通道中设置一个基,以此二维时频图像转换成具有3个通道的二维图像,各二维时频图像转换结果如图6所示。Specifically, the image resolution of the two-dimensional time-frequency image input to the convolutional neural network is a 3-channel image of 224*224, the batch is 21, the initial learning rate is set to 0.0001, the optimization function uses adam, the number of training rounds is 12, and the activation function is ReLU. Because the RGB image input to the two-dimensional convolutional neural network has certain requirements on the size, it is necessary to perform image preprocessing on the two-dimensional time-frequency image converted by the continuous wavelet transform. Since it is characterized by a single-channel grayscale image, the grayscale image is copied to 3 channels and a basis is set in each channel, so that the two-dimensional time-frequency image is converted into a two-dimensional image with 3 channels. The conversion results of each two-dimensional time-frequency image are shown in Figure 6.
步骤(4a):以下使用直径24mm钢丝绳的断丝数据对卷积神经网络模型进行训练验证,使用8类内外部断丝的漏磁信号转换的二维时频图像作为卷积神经网络的输入进行损伤识别,并选取其中70%进行模型训练,选取其中30%进行模型验证。为了使该深度学习模型达到最优配置,设计了多种结构参数的卷积神经网络模型,如表1.1列出了15种不同结构和参数的模型。Step (4a): The following uses the broken wire data of 24mm diameter steel wire rope to train and verify the convolutional neural network model, and uses the two-dimensional time-frequency images converted from the leakage magnetic signals of 8 types of internal and external broken wires as the input of the convolutional neural network for damage identification, and selects 70% of them for model training and 30% for model verification. In order to achieve the optimal configuration of the deep learning model, convolutional neural network models with various structural parameters are designed, as shown in Table 1.1, which lists 15 models with different structures and parameters.
表1.1.不同结构和不同参数下卷积神经网络的分类结果Table 1.1. Classification results of convolutional neural networks with different structures and parameters
注:(格式“Si,Ni”表示卷积神经网络的卷积层的“卷积核大小,卷积核数量”;“SSi”是池化层中池化窗的尺寸,“i”代表第i个卷积层或池化层。)Note: (The format “S i ,N i ” represents the “convolution kernel size, number of convolution kernels” of the convolutional layer of the convolutional neural network; “S Si ” is the size of the pooling window in the pooling layer, and “i” represents the i-th convolutional layer or pooling layer.)
从表1.1可以看出,卷积神经网络模型的结构和参数不同时,对钢丝绳断丝漏磁信号检测的准确率也不同,但其中标号15所测准确率达到了99.58%,所以由三个卷积层、三个最大池化层和一个全连接层组成的CNN模型被选为钢丝绳故障智能识别模型,此时保存模型各项结构和参数,其详细参数如表1.2所示。即以MATLAB语言基于Simulink库搭建三个卷积层、三个最大池化层和一个全连接层组成的卷积神经网络定量识别模型。As can be seen from Table 1.1, when the structure and parameters of the convolutional neural network model are different, the accuracy of detecting the broken wire leakage signal of the wire rope is also different, but the accuracy of the
表1.2.选定卷积神经网络的具体参数Table 1.2. Specific parameters of selected convolutional neural networks
如表所示,标号15采用了三层二维卷积结构,卷积核大小为11,三层卷积核的数量分别为8、12、12,池窗尺寸均为2。池化层在卷积层之后对卷积层提取的特征信息进行降维处理,均使用最大值池化函数,池化大小为2×2,步长为2。最后全连接层输出8个变量,即对应于8种类型的钢丝绳断丝。经标号15模型所采集的8类断丝训练曲线和误差曲线如图7所示,可得出训练曲线和误差曲线在经过12轮的模型训练后趋于稳定,其准确率高达99.58%,误差率仅为0.44%。As shown in the table,
步骤(4b):所选定标号15模型的结构和参数设置全部完毕,对8类钢丝绳故障的二维时频图像在经卷积神经网络模型的多层处理后,采用t-SNE算法对其特征信息可视化后,如图8所示,其结果形成了8种明显且易分类的损伤特征。由此说明基于卷积神经网络的钢丝绳故障智能识别能够对钢丝绳损伤特征准确分类。Step (4b): The structure and parameter settings of the selected model No. 15 are all completed. After the two-dimensional time-frequency images of the eight types of wire rope faults are processed by the multi-layer convolutional neural network model, the characteristic information is visualized using the t-SNE algorithm, as shown in Figure 8. The result forms eight obvious and easily classified damage features. This shows that the intelligent recognition of wire rope faults based on convolutional neural networks can accurately classify wire rope damage features.
步骤(4c):为了进一步验证钢丝绳故障的分类结果,基于误差矩阵对8类钢丝绳故障的二维时频图像再次进行可视化分析,其分析结果如图9所示。误差矩阵中行表示预测数据(输出类),其列表示实际数据(目标类),对角线单元为正确值,非对角线单元则表示错误分类数据,误差矩阵每个单位中都会显示其分类结果的数量和百分率。可由图中得出,基于卷积神经网络模型对直径24mm钢丝绳故障类型进行了显著划分,仅第一种故障类型存在一个错误标签,但总体来说对分类结果没有影响,其他七种故障类型的分类准确率都达到了100%。进一步说明基于卷积神经网络的钢丝绳故障智能识别可以通过钢丝绳各类断丝信号转换成的二维时频图像进行准确的分类。Step (4c): In order to further verify the classification results of wire rope faults, the two-dimensional time-frequency images of 8 types of wire rope faults are visualized again based on the error matrix, and the analysis results are shown in Figure 9. The rows in the error matrix represent the predicted data (output class), the columns represent the actual data (target class), the diagonal units are correct values, and the non-diagonal units represent the misclassified data. The number and percentage of the classification results are displayed in each unit of the error matrix. It can be seen from the figure that the convolutional neural network model significantly divides the fault types of 24mm diameter wire ropes. Only the first fault type has an incorrect label, but it has no effect on the classification results overall. The classification accuracy of the other seven fault types has reached 100%. It further illustrates that the intelligent identification of wire rope faults based on convolutional neural networks can accurately classify the two-dimensional time-frequency images converted from various wire rope broken wire signals.
步骤(4d):与现有传统钢丝绳故障分类识别方法BP神经网络与本发明所提出的方法进行对比。以步骤1所采集到的直径为24mm钢丝绳8类内外部损伤信号作为BP神经网络的输入信号,得出的BP网络模型训练结果以误差矩阵表达,如图10所示。可以看出,BP神经网络最终分类的准确率仅为84.2%,卷积神经网络分类的整体准确率为99.6%,BP远低于CNN所得到的准确率。其中第一种和第四种故障类型的分类结果损失率较大,分别为48.6%和48.1%。也可从误差矩阵其他单位中看出,第一类故障类型和第二类在分类时发生了混淆,第四类故障类型也和第三类发生了混淆。将误差矩阵图9与图10相比,本发明所使用的基于卷积神经网络的钢丝绳故障智能识别在准确率和损失率上都具有显著性的优势。Step (4d): Compare the method proposed in the present invention with the existing traditional wire rope fault classification and identification method BP neural network. The 8 types of internal and external damage signals of the wire rope with a diameter of 24mm collected in
步骤5:将训练好的卷积神经网络模型用于钢丝绳故障识别系统中,输入钢丝绳损伤检测传感器采集的信号,通过步骤(4)的卷积神经网络模型进行处理。Step 5: Use the trained convolutional neural network model in the wire rope fault identification system, input the signal collected by the wire rope damage detection sensor, and process it through the convolutional neural network model of step (4).
以上所述仅为本申请的优选实施案例而已,并不用于限制本申请,对于本领域的技术人员来说,本申请可以有各种更改和变化。凡在本申请的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本申请的保护范围之内。The above is only a preferred implementation case of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.
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| CN117194955A (en) * | 2023-09-28 | 2023-12-08 | 盛东如东海上风力发电有限责任公司 | Submarine cable broken wire quantitative analysis acquisition method based on magnetic signals |
| CN118734082A (en) * | 2024-09-04 | 2024-10-01 | 成都大学 | A landslide deformation prediction method based on data enhancement strategy |
| CN119226018A (en) * | 2024-09-13 | 2024-12-31 | 上海至盛信息技术股份有限公司 | A computer system fault detection method and system based on artificial intelligence |
| CN119395130A (en) * | 2024-12-31 | 2025-02-07 | 联桥网云信息科技(长沙)有限公司 | A rapid electromagnetic nondestructive detection method for PCCP pipeline broken wires |
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| CN117194955A (en) * | 2023-09-28 | 2023-12-08 | 盛东如东海上风力发电有限责任公司 | Submarine cable broken wire quantitative analysis acquisition method based on magnetic signals |
| CN118734082A (en) * | 2024-09-04 | 2024-10-01 | 成都大学 | A landslide deformation prediction method based on data enhancement strategy |
| CN119226018A (en) * | 2024-09-13 | 2024-12-31 | 上海至盛信息技术股份有限公司 | A computer system fault detection method and system based on artificial intelligence |
| CN119395130A (en) * | 2024-12-31 | 2025-02-07 | 联桥网云信息科技(长沙)有限公司 | A rapid electromagnetic nondestructive detection method for PCCP pipeline broken wires |
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