Machinery Condition Monitoring and Intelligent Fault Diagnosis, 2nd Edition

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Machines Testing and Maintenance".

Deadline for manuscript submissions: closed (30 June 2025) | Viewed by 1215

Special Issue Editors


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Guest Editor
School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, China
Interests: prognostics and health management; mechatronics technology; intelligent robot; high-speed structure design and dynamic analysis
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
School of Computing and Artificial Intelligence, Southwest Jiaotong University, Chengdu 611756, China
Interests: tool condition monitoring; machine vision; deep learning
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Machinery condition monitoring and intelligent fault diagnosis have recently come to play a crucial role in automatic and intelligent industrial production processes. Based on machine learning, deep learning, and artificial intelligence, intelligent fault diagnosis was proposed, achieving remarkable improvements, especially in the face of unknown nonlinear machine behaviors and non-stationary data. However, there are still some problems in machinery condition monitoring and intelligent fault diagnosis that require further research, such as early fault detection features, multi-modal data fusion, and small-sample machine, multi-condition transfer, and interpretable deep learning algorithms.

To comprehensively report on the research progress in this field, disseminate excellent research results, and promote the development and application of machinery condition monitoring and intelligent fault diagnosis, this Special Issue presents advances in intelligent fault diagnosis algorithms, fault feature extraction, and intelligent machine monitoring.

This Special Issue includes, but is not limited to, the following topics:

  • failure mechanism modeling for mechanical equipment; 
  • monitoring signal processing for mechanical equipment; 
  • intelligent feature extraction for condition monitoring;
  • intelligent early fault detection and diagnosis;
  • few-shot sample learning for fault detection;
  • transfer learning-based methods for fault diagnosis;
  • interpretable deep learning for fault diagnosis;
  • hybrid models of data-driven and model-based approaches;
  • sensor data fusion for fault diagnosis;
  • measurement methods, technologies, and systems for fault diagnosis.

Prof. Dr. Hongli Gao
Dr. Zhichao You
Guest Editors

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Keywords

  • failure mechanisms modeling for mechanical equipment
  • monitoring signal processing for mechanical equipment
  • intelligent feature extraction for condition monitoring
  • intelligent early fault detection and diagnosis
  • few-shot sample learning for fault detection
  • transfer-learning-based methods for fault diagnosis
  • interpretable deep learning for fault diagnosis
  • hybrid models of data-driven and model-based approaches sensor data fusion for fault diagnosis
  • measurement methods, technologies, and systems for fault diagnosis

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Related Special Issue

Published Papers (2 papers)

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Research

14 pages, 12187 KiB  
Article
Magnetic Field Simulation and Torque-Speed Performance of a Single-Phase Squirrel-Cage Induction Motor: An FEM and Experimental Approach
by Jhonny Barzola and Jonathan Chandi
Machines 2025, 13(6), 492; https://doi.org/10.3390/machines13060492 - 5 Jun 2025
Viewed by 456
Abstract
This study presents a detailed investigation of the torque-speed characteristics of a WEG single-phase squirrel-cage induction motor (SPSCIM) of (1/2 hp), 110/220 V at 60 Hz. The primary objective was to derive the motor’s equivalent circuit and validate its performance curves through finite [...] Read more.
This study presents a detailed investigation of the torque-speed characteristics of a WEG single-phase squirrel-cage induction motor (SPSCIM) of (1/2 hp), 110/220 V at 60 Hz. The primary objective was to derive the motor’s equivalent circuit and validate its performance curves through finite element analysis (FEA), simulation using MATLAB®/Simulink®, and experimental testing. Finite element simulations were conducted using the software FEMM (Finite Element Method Magnetics) to model the magnetic flux distribution within the motor’s stator and rotor. These simulations, based on the motor’s dimensions and nameplate data, provided essential insights into the electromagnetic behavior, including flux density and saturation effects, which are crucial for accurate torque-speed curve predictions. For experimental validation, tests were performed under open-circuit and locked-rotor conditions through a universal machine as a load emulator. The torque-speed characteristics were determined using the Suhr method and the classical approach, with the resulting curves compared to experimental measurements. Voltage and current were measured using AC PZEM-004T and DC PZEM-017 meters, while rotor speed was monitored with a Hall effect sensor (A3144). The results revealed strong agreement between the FEM simulations, Surh method, and experimental data, demonstrating the reliability and accuracy of the combined simulation and analytical methods for modeling the motor’s performance. The estimations using classical and Suhr methods, Simulink simulations, and FEMM yielded low error percentages, mostly below 2%. However, in the FEMM simulation, rotor resistance showed a higher error of around 20% due to unavailable data on the exact number of windings turns, a modifiable parameter that can be corrected through further adjustments in the simulation. The torque-speed curves obtained at different voltage levels showed an excellent correlation, confirming the effectiveness of the proposed approach in characterizing the motor’s operational behavior. Full article
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18 pages, 4863 KiB  
Article
Fault Diagnosis in a 2 MW Wind Turbine Drive Train by Vibration Analysis: A Case Study
by Rafael Tuirán, Héctor Águila, Esteve Jou, Xavier Escaler and Toufik Mebarki
Machines 2025, 13(5), 434; https://doi.org/10.3390/machines13050434 - 20 May 2025
Viewed by 501
Abstract
This paper presents a vibration analysis method for detecting typical faults in gears of the drive train of a 2 MW wind turbine. The data were collected over a one-year period from an operating wind turbine with a gearbox composed of one planetary [...] Read more.
This paper presents a vibration analysis method for detecting typical faults in gears of the drive train of a 2 MW wind turbine. The data were collected over a one-year period from an operating wind turbine with a gearbox composed of one planetary stage and two helical gear stages. Failures in two pairs of helical gears were identified: one involving pitting and wear in the gears connecting the intermediate-speed shaft to the low-speed shaft, and another one involving significant material detachment in the gears connecting the intermediate-speed shaft to the high-speed shaft. The continuous evaluation of time signals, frequency spectra, and amplitude modulations allowed the most sensitive sensors and frequencies for predicting surface damage on gear teeth in this type of turbine to be determined. A steady-state frequency analysis was performed, enabling the detection of the aforementioned surface faults. This approach is simpler compared with more complex transient-state techniques. By tracking vibration signals over time, the importance of analyzing gear mesh frequencies and their harmonics was highlighted. Additionally, it was found that the progression of gear damage was dependent on the power output of the wind turbine. As a result, the most appropriate ranges of power were identified, within which the evolution of the vibration measurement was associated with the damage evolution. Since many turbines currently in operation have similar designs and power output levels, the present findings can serve as a guideline for monitoring an extensive number of units. Full article
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