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Oct 18, 2018 - in order to determine K adaptively, Permutation Entroy Optimization (PEO) is .... x(i + (j1 − 1)τ) ≤ x(i + (j2 − 1)τ) ≤ ... ≤ x(i + (jm − 1)τ). (2). Step 3: If there ..... (2) Initialize K and determine the best K value by Permutation Entroy;.
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Research on Fault Diagnosis of Gearbox with Improved Variational Mode Decomposition Zhijian Wang, Junyuan Wang * and Wenhua Du College of Mechanical Engineering, North University of China, Taiyuan 030051, China; [email protected] (Z.W.); [email protected] (W.D.) * Correspondence: [email protected] or [email protected]; Tel.: +86-186-3616-2629 Received: 31 August 2018; Accepted: 26 September 2018; Published: 18 October 2018

 

Abstract: Variational Mode Decomposition (VMD) can decompose signals into multiple intrinsic mode functions (IMFs). In recent years, VMD has been widely used in fault diagnosis. However, it requires a preset number of decomposition layers K and is sensitive to background noise. Therefore, in order to determine K adaptively, Permutation Entroy Optimization (PEO) is proposed in this paper. This algorithm can adaptively determine the optimal number of decomposition layers K according to the characteristics of the signal to be decomposed. At the same time, in order to solve the sensitivity of VMD to noise, this paper proposes a Modified VMD (MVMD) based on the idea of Noise Aided Data Analysis (NADA). The algorithm first adds the positive and negative white noise to the original signal, and then uses the VMD to decompose it. After repeated cycles, the noise in the original signal will be offset to each other. Then each layer of IMF is integrated with each layer, and the signal is reconstructed according to the results of the integrated mean. MVMD is used for the final decomposition of the reconstructed signal. The algorithm is used to deal with the simulation signals and measured signals of gearbox with multiple fault characteristics. Compared with the decomposition results of EEMD and VMD, it shows that the algorithm can not only improve the signal to noise ratio (SNR) of the signal effectively, but can also extract the multiple fault features of the gear box in the strong noise environment. The effectiveness of this method is verified. Keywords: gearbox; multiple fault features; permutation entropy optimization; Variational Mode Decomposition

1. Introduction Gearbox is widely used in many mechanical equipment, and is the key component of equipment operation [1]. However, due to the complicated working environment and improper maintenance of the gearbox, the gearbox is prone to malfunction during its working process [2]. Due to the complexity of the internal structure of the gearbox, when a fault occurs, the fault type is mostly complex, and its fault features are often drowned in the strong background noise. Therefore, an effective feature extraction method is needed [3–5]. In 2014, Dragomiretskiy proposed a new signal processing algorithm, namely Variational Mode Decomposition [6]. Compared with EMD and EEMD, the algorithm has a solid theoretical foundation and high resolution accuracy [7]. Yet, the algorithm needs to set the number of decomposition layers K in advance, and the K values are often determined only by personal experience [8]. Therefore, the decomposition results are easily affected by human factors and the phenomenon of over-decomposition or under-decomposition occurs easily. That is, when K is too high, it will cause over-decomposition and decompose abnormal white noise components. Nevertheless, when the K value is too small, the phenomenon of under-decomposition will occur and some of the fault features cannot be extracted [9,10]. In addition, VMD is sensitive to noise [11], that is, the decomposition results Sensors 2018, 18, 3510; doi:10.3390/s18103510

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are easily affected by the background noise, especially in the strong background noise environment, it is easier to produce false components caused by noise [12]. While for subsequent fault identification [13], the generation of false components can easily lead to misdiagnosis [14]. For the adaptive determination of the decomposition layer number K, Yi, and Lv are using the Particle Swarm Optimization (PSO) [15] to determine the decomposition level of K in VMD. Zhang and others optimize the parameters of the algorithm by using the Grasshopper Optimization Algorithm (GOA) [16]. In addition, other scholars use the ant colony algorithm (ACO) [17], artificial fish swarm algorithm (AFSA) [18], and other optimization algorithms to optimize the parameters in the VMD. Compared to the K value determined by personal experience, these optimization algorithms can automatically determine the K value based on the original signal, and have good adaptability, and the effect of human factors on the decomposition results is excluded. However, all of these algorithms are Meta-heuristic algorithms. The principle of these algorithms is a parameter optimization algorithm designed by simulating the foraging behavior of the cluster animals. In order to ensure the precision of optimization, a large population density is usually required [19]. Based on the randomness detection of the permutation entropy, this paper proposes a Permutation Entroy optimization (PEO) in order to adaptively determine the parameter K in VMD. The principle of the algorithm is to calculate the entropy of each intrinsic modal function decomposed by the original signal. As the anomalous component is random, its permutation entropy is much larger than the normal component [20]. Thus, after setting the threshold of the permutation entropy, whether the permutation entropy of each layer of IMF is greater than the threshold value is judged, so as to determine whether there is an abnormal component in the decomposition result, that is, whether there is an over decomposition at this time. VMD is used to decompose the original signal, until the decomposition results have abnormal components, it shows that the decomposition occurs right now, and then the K value at this time is reduced by one as the final optimization value. In order to improve the signal to noise ratio(SNR) and reduce the sensitivity of VMD to noise, the author draws inspiration from the idea of Noise Aided Data Analysis (NADA) [21], and proposes a method of reducing noise based on VMD, that is, the Modified VMD (MVMD). At the same time, in order to reduce the reconstruction error and make the white noise to be completely neutralized, this algorithm uses the idea of adding white noise pairs in the Complete Ensemble Empirical Mode Decomposition (CEEMD) [22]. In each cycle, two white noises with equal amplitude and opposite sign are added to the original signal. Then the VMD is used to decompose it, and the noise in the original signal will offset each other after repeated cycles. The IMF of each layer of each cycle is integrated, and then the signal is reconstructed according to the result of the integrated mean. The reconstructed signal is decomposed by MVMD. The analysis results of simulation and experimental signals show that the decomposition result of the algorithm is better than that of VMD. 2. Principles of the Algorithm 2.1. The Principle of Permutation Entropy Algorithm Permutation Entropy (PE) [23] is a method proposed by Bandt et al. to detect the randomness and dynamic mutation of time series. This algorithm has the advantages of simple principle, high computational efficiency, and good robustness. It is very suitable for nonlinear data analysis [24]. The specific steps of the algorithm are as follows. Step 1: Given a discrete time series { x (i ), i = 1 ∼ N }. Phase space reconstructionfor each element in the time series. Get the refactoring matrix as shown in the following formula.       

x (1) ... x ( j) ... x (K )

x (1 + τ ) ... x( j + τ ) ... x (K + τ )

... ... ... ... ...

x (1 + ( m − 1) τ ) ... x ( j + ( m − 1) τ ) ... x ( K + ( m − 1) τ )

      

(1)

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Among them, j = 1 ∼ K, K is the number of reconstructed components. m is the embedding dimension. τ is the delay time. x ( j) represents the j row component of the reconstruction matrix. Step 2: According to the ascending rule, the reconstruction matrix of each row is arranged, and the result is shown in Equation (2). x (i + ( j1 − 1)τ ) ≤ x (i + ( j2 − 1)τ ) ≤ . . . ≤ x (i + ( jm − 1)τ )

(2)

Step 3: If there is an equal value in the component, that is, when x (i − ( j1 − 1)τ ) = x (i − ( j2 − 1)τ ) occurs, then sort according to the size of the j value. That is, when j1 < j2 , there is x (i − ( j1 − 1)τ ) ≤ x (i − ( j2 − 1)τ )

(3)

Step 4: For every row of the reconstructed matrix, a row of symbol sequences S(l ) = ( j1 , j2 , . . . , jm ) can be obtained. Among them, l = 1 ∼ k, k ≤ m!. That is to say, in the m dimensional phase space mapping, different symbol sequences of m! group can be obtained, and S(l ) belongs to one of them. Step 5: The probability of each S(l ) appears with P1 , P2 , . . . , Pk , respectively. The permutation entropy formula of the symbol sequence of k time series x (i ) at different time is shown in Equation (4). k

HP (m) = − ∑ Pj ln Pj

(4)

j =1

That is, k

PEP (m) = HP (m) = − ∑ Pj ln Pj

(5)

j =1

2.2. Principle of VMD The specific construction steps of the constrained variational model are as follows. Step 1: For the input signal x (t), through the Hilbert Transform (HT), we can get the analytic signal of each modal function uk (t). Step 2: The center frequency ωk of each modal function uk (t) is estimated, and its spectrum is moved to the baseband. Step 3: After that, the bandwidth is estimated through the H 1 Gauss smoothness. The final constraint variational model can be expressed by Formula (6).   

 h

min ∑

∂t (σ (t) + (u )(ω ) k

k

k

j πt ) uk ( t )

i

2 

e− jωk t

2

  s.t.∑ uk = x (t)

(6)

k

In the equation, ∂t means partial derivative to t, δt is the impulse function, and {uk } = {u1 , . . . , uK } represents the K IMFs obtained by the VMD for the original signal x (t), and {ωk } = {ω1 , . . . , ωK } represents the central frequency of each IMF component. In order to solve the optimal solution of the above variational model, the following forms of Lagrange function are introduced

2

j L({uk }, {ωk }, λ) = α ∑ [(σ(t) + πt ) × uk (t)]e− jωk t 2 k

2  

+

x ( t ) − ∑ u k ( t ) + λ ( t ), x ( t ) − ∑ u k ( t ) k

2

k

In the equation, λ is a Lagrange multiplier and α is a penalty factor.

(7)

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Secondly, the Lagrange function of Equation (7) is transformed in time-frequency domain, and the corresponding extremum solution is carried out. The frequency domain expression of the modal function uk and the central frequency ωk can be obtained. ∧ ∧ n +1 uk (ω )

=





f ( ω ) − ∑i 6=k ui ( ω ) +

λ(ω ) 2

(8)

1 + 2α(ω − ωk )2

ωkn+1 =

2 R∞ ∧ ω uk (ω ) dω 0

(9)

2 R∞ ∧ u ( ω ) dω k 0

Finally, the optimal solution of the constrained variational model is solved by using the Alternate Direction Method of Multipliers (ADMM), and the original signal x (t) is decomposed into K IMFs. The specific steps of the algorithm are as follows.  1  1 ∧1 ∧ ∧ Step 1: The initialization of the parameters, set uk , ω k , λ and n to 0. ∧



Step 2: Update uk and ω k according to Equations (8) and (9). ∧ n +1

Step 3: Update the value of λ

Step 4: Until the equation

∧ n +1

according to equation λ



∧ n +1 ∧ n 2

∑k

uk −uk 2



∧n

uk



∧n



∧ n +1

(ω ) = λ (ω ) + τ ( f (ω ) − ∑ uk

(ω )).

k

< ε is satisfied, the iteration is stopped and the loop is

exited. Otherwise, the return step 2. Finally, K intrinsic mode functions can be obtained. 3. Improvement of VMD Aiming at the problem of VMD, this paper adopts the permutation entropy optimization algorithm to adaptively determine the number of decomposition layers, and uses the Modified VMD to reduce the noise of the original signal and finish the final decomposition. The following two algorithms are introduced, respectively. 3.1. Permutation Entroy Optimization Algorithm (PEO) First, the permutation entropy values of the following simulation signals are calculated, respectively. Among them, x1 = sin(2 × π × 30), x2 = sin(2 × π × 120), x3 = sin(2 × π × 250) are sinusoidal signals. x4 = (1 + cos(2 × π × 12)) sin(2 × π × 120) is an amplitude modulation g signal. x5 (t) = Am × exp(− Tm ) sin(2π f c t) is a periodic shock signal, among them, Am = 2, damping coefficient g = 0.1, oscillation period Tm = 0.1, natural frequency f c = 160 Hz. x6 is Gauss white noise with a length of 2048. The permutation entropy values of the above simulation signals are calculated, respectively, and the histogram as shown in Figure 1 is shown. In order to make the experiment have better reliability, it can be known that the PE of different energy is solved. As the noise amplitude increases, PE also increases gradually, but both are greater than 0.6. When the amplitude and frequency of the modulated signal and the impulse signal change, the change of PE is small, and both are less than 0.6. As shown in Tables 1–3. Table 1. The permutation entropy values corresponding to different noise amplitude. Amplitude

0.2

0.5

0.8

1

1.5

2

PE

0.6524

0.7832

0.8231

0.8937

0.9435

0.9846

the change of PE is small, and both are less than 0.6. As shown in Tables 1–3. Table 1. The permutation entropy values corresponding to different noise amplitude.

Amplitude PE

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0.2 0.6524

0.5 0.7832

0.8 0.8231

1 0.8937

1.5 0.9435

2 0.9846

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Table 2.2.The Thepermutation permutationentropy entropy values corresponding to different frequency of modulation Table values corresponding to different frequency of modulation signal.

signal. Frequency

Frequency PE PE

80

80 0.3822 0.3822

120

120 0.3835 0.3835

180

240

180 240 0.3876 0.3926 0.3876 0.3926

300

360

300 0.3935 0.3935

360 0.3921

0.3921

Table 3. The permutation entropy values corresponding to different amplitude of impulse signal. Table 3. The permutation entropy values corresponding to different amplitude of impulse signal. Amplitude

1.5

2

Amplitude 1.5 2 PE 0.4821 PE 0.4824 0.4824 0.4821

2.5

2.5 0.4838 0.4838

3

3.5

3 0.4872 0.4872 0.4905

4

3.5 0.4931 0.4905

4 0.4931

Figure Figure 1. 1. The permutation entropy entropy value value of of each each simulation simulation signal. signal.

According According to to the the above above histogram, histogram, the the permutation permutation entropy entropy of of sinusoidal sinusoidal signal signal and and amplitude amplitude modulation signal is small. The permutation entropy of periodic impact signals is slightly larger modulation signal is small. The permutation entropy of periodic impact signals is slightly larger than than that of sinusoidal and amplitude modulated signals, but neither of them exceeds the empirical that of sinusoidal and amplitude modulated signals, but neither of them exceeds the empirical threshold threshold of of 0.6. 0.6. However, However, the the permutation permutation entropy entropy of of white white noise noise is is very very large large and and far far higher higher than than the threshold. It shows that the Gauss white noise sequence is more random and the probability the threshold. It shows that the Gauss white noise sequence is more random and the probability of of dynamic dynamic mutation mutation is is larger, larger, which which is is also also consistent consistent with with the the reality. reality. Therefore, Therefore, through through the the above above analysis, that according to the entropy value,value, we canwe distinguish normal normal signals analysis,we wecan cansee see that according to permutation the permutation entropy can distinguish from abnormal signals. Based on the randomness detection of the permutation entropy, this paper signals from abnormal signals. Based on the randomness detection of the permutation entropy, this proposes a permutation. Entroy optimization (PEO) in order to adaptively determine the parameter K in the VMD. The principle of the algorithm is to calculate the entropy of each intrinsic modal function decomposed by the original signal. As the anomalous component is random, its permutation entropy is much larger than the normal component. Thus, after setting the threshold of the permutation entropy, whether the permutation entropy of each layer of IMF is greater than the threshold value is judged, so as to determine whether there is an abnormal component in the decomposition result, that is, whether there is an over decomposition at this time. If not, we need to continue to increase the number of decomposition layers, that is, the number of decomposition layers needs to increase by one, and then according to the updated K value, the VMD is used to decompose the original signal, until the decomposition results have abnormal components, it shows that the decomposition occurs right now, and then the K value at this time is reduced by one as the final optimization value. The concrete steps of the algorithm are as follows: (1) (2) (3) (4)

The initial value of setting K is 2, and the threshold of permutation entropy is taken as an empirical value 0.6. VMD is used to decompose the original signal and get K intrinsic mode functions imfi (t) (i = 1 ∼ K). The permutation entropy pei (i = 1 ∼ K ) of each IMF in the decomposition results is calculated, respectively. Whether there is a greater than a threshold of 0.6. If there is an explanation that the decomposition result is over decomposed to cause abnormal components, then it is necessary to stop the loop

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and enter the step (5). If not, there is no over decomposition. The original signal also needs to increase the number of decomposition layers, that is, K = K + 1, and will return to step (2). According to the updated K value, we continue to decompose the original signal by VMD. The condition of the loop termination is that the current K value makes the decomposition result exactly the abnormal component of the permutation entropy greater than the threshold value, that is, the K value set at this time causes the VMD over decomposition. Therefore, it is necessary to update the K value before output as the final result, so that K = K − 1 can be used as the optimal solution output of the decomposition level.

3.2. Modified VMD (MVMD) In order to improve signal-to-noise ratio (SNR) and reduce the sensitivity of VMD to noise, the author, inspired by the idea of Noise-Aided Data Analysis (NADA), proposed a method of noise reduction based on VMD, that is, the modified VMD (MVMD). The principle of this algorithm is to add auxiliary Gauss white noise to the original signal and make use of the uniform distribution of white noise to change the extreme distribution of the signal. After repeated cycles and integrated averages, the noise in the original signal will be greatly offset, thus achieving the purpose of homogenizing the noise in the original signal. At the same time, in order to reduce the reconfiguration error and make the white noise to be completely neutralized. This algorithm adopts the idea of adding white noise pairs in the CEEMD. That is, the white noise added in each cycle is two positive and negative white noise pairs with the same amplitude and the opposite symbol. This can guarantee the noise reduction while not increasing the new noise. After adding auxiliary white noise, two signals to be decomposed will be obtained, and then the VMD is used to decompose them, respectively. After repeated cycles, the noise in the original signal will be counterbalanced. Finally, the IMF of each layer obtained by each cycle is integrated averaging, and then the signal is reconstructed according to the result of ensemble mean. The reconstructed signal is decomposed by VMD again as the final result of MVMD. The specific steps of the algorithm are as follows: Step 1: Initialize the parameter settings. Determine the K value according to the PEO algorithm. At the same time, set the number of cycles N and the amplitude of white noise Nstd. Step 2: By adding the positive and negative Gauss white noise pairs with Nstd amplitude to the original signal, two decomposed signals xi1 (t) and xi2 (t) can be obtained. (

xi1 (t) = x (t) + noisei (t) xi2 (t) = x (t) − noisei (t); (i = 1 ∼ N )

(10)

Step 3: The two decomposed signals xi1 (t) and xi2 (t) are decomposed by VMD, respectively, and two groups of IMFs can be obtained. As shown by Equation (11). (

imf1ij (t) imf2ij (t)

( j = 1 ∼ K) ( j = 1 ∼ K)

(11)

The imf1ij (t) represents the jth IMF component of the signal xi1 (t) after the ith decomposition, imf2ij (t) represents the jth IMF component of the signal xi2 (t) after the ith decomposition. Step 4: Repeat steps 2 and step 3 N times, and add a new Gauss white noise pair at the beginning of each cycle. Step 5: After N cycles, the final 2 × N × K IMF is integrated and the result is shown in formula 12. imf j (t) =

 1 N im f 1 ( t ) + im f 2 ( t ) , ( j = 1 ∼ K) ij ij 2N i∑ =1

(12)

where imf j (t) represents the ensemble mean of the j level IMF component in all decomposition results.

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Step 6: The reconstructed signal is reconstructed according to the result of ensemble mean, as shown in Equation (13). K

x0 ( t ) =

∑ im f j (t), ( j = 1 ∼ K)

(13)

j =1

Step 7: The VMD is used to decompose the reconstructed signal x0 (t), and K IMFs is obtained as the final result of MVMD. Flow chart of MVMD based on PEO in Figure 2. The specific steps are as follows (1) (2) (3) (4) (5)

Input signal; Initialize K and determine the best K value by Permutation Entroy; Add the opposite white noise to the signal and perform MVMD decomposition; Refactoring the decomposed signal; Determine of the composite fault by spectrum analysis. Sensors 2018, 18, xthe FORlocation PEER REVIEW

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Figure 2. Flow chart of the Permutation Entroy Optimization- Modified Variational Mode Figure 2. Flow chart of the Permutation Entroy Optimization- Modified Variational Mode Decomposition (PEO-MVMD). Decomposition (PEO-MVMD).

4. Simulation Signal Analysis

4. Simulation Signal Analysis

4.1. Construction of Simulation Signal

4.1. Construction of Simulation Signal

Gears and bearings components,and and they also prone to fatigue damage. Gears and bearingsare aretwo twoimportant important components, they areare also prone to fatigue damage. When thethe gearbox has compound vibrationsignals signalsare areusually usually with multiple modulation When gearbox has compoundfaults, faults, the the vibration with multiple modulation sources. Therefore, in the construction of the simulation signal, the simulation and analysis of the gear fault simulation signal and the rolling bearing fault simulation signal are used in this paper. The simulation signal is constructed as follows.

x(t )  x1 (t )  x2 (t )  x3 (t )  0.5  randn(t )

(14)

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sources. Therefore, in the construction of the simulation signal, the simulation and analysis of the gear fault simulation signal and the rolling bearing fault simulation signal are used in this paper. The simulation signal is constructed as follows. x (t) = x1 (t) + x2 (t) + x3 (t) + 0.5 × randn(t)

(14)

The composition signal x1 (t) = 2 sin(2π f 1 t) is a sine signal. The composition signal x2 (t) = (1 + cos(2π f n1 t) + cos(2π f n2 t)) sin(2π f z t) is a gear fault simulation signal containing two modulation sources, where f n1 and f n2 are modulation frequencies, and f z is the carrier frequency, Sensors x FOR PEER REVIEWof gears. The component signal x (t ) = A × exp(− g ) sin(2π f t9)of 16 that is,2018, the 18, meshing frequency m c is a 3 Tm periodic shock signal, which is used to simulate the fault signal of the rolling bearing, in which Am fc g isshock, Tm is thethe represents thethe amplitude of the the g is the dampingthe coefficient, Tmof is shock, the cycle shock, amplitude of shock, the the damping coefficient, cycle andofthe and f c is the rotation frequency of theThe bearing. The parameters in the following is thethe rotation frequency of the bearing. parameters are shownare in shown the following Table 4. Table 4. Table 4. Table 4. The The parameters parameters of of the the simulation simulation signal. signal.

f1

f1

f n1

f n1

f n 2 f n2

fz

fz

12 Hz 20 Hz 20 Hz 120120 28 Hz28 Hz12 Hz HzHz

AmAm

gg

TT m

2 2

0.1 0.1

0.1 0.1

m

fc

fc

280 280

Set the sampling points N toN3000, and the sampling frequency is 1500Hz.The thenumber numberofof sampling points to 3000, and the sampling frequency is 1500timeHz. x ( t ) x ( t ) x ( t ) x ( t ) The time-domain waveforms of the component signal x ( t ) , x ( t ) , x ( t ) , and the simulation signal x (t) 1 2 3 2 3 domain waveforms of the component signal , 1 , , and the simulation signal are are shown in Figure 3. Through the spectrum analysis, the carrier frequency and the natural frequency shown in Figure 3. Through the spectrum analysis, the carrier frequency and the natural frequency of can bebe extracted. However, thethe natural frequency has of the the impact impact signal signalininthe thecomposite compositefault faultsignal signal can extracted. However, natural frequency ahas small amplitude and is easily disturbed by noise. a small amplitude and is easily disturbed by noise.

x1 (t )

x2 (t )

x3 (t )

x (t )

Figure spectrum. Figure 3. 3. The The time time domain domain waveform waveform of of each each component component signal signal and and its its spectrum.

4.2. Adaptive Determination of Decomposition Layer K by PEO Algorithm First, we use the PEO algorithm to determine the decomposition level K, set the initial value of K to two. Find out the optimal value of K according to whether or not there is over decomposition. After each cycle iteration, the permutation entropy of each IMF of the original signal decomposed by

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4.2. Adaptive Determination of Decomposition Layer K by PEO Algorithm First, we use the PEO algorithm to determine the decomposition level K, set the initial value of K to two. Find out the optimal value of K according to whether or not there is over decomposition. After each cycle iteration, the permutation entropy of each IMF of the original signal decomposed by VMD is calculated. As shown in the following Figure 4. Sensors 2018, 18, x FOR PEER REVIEW

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Figure 4. Permutation entropy IntrinsicMode Mode Functions Functions (IMF) iteration of PEO algorithm Figure 4. Permutation entropy ofof Intrinsic (IMF)inineach each iteration of PEO algorithm different K value in the VMD. with with different K value in the VMD. Figure 4. Permutation entropyresult of Intrinsicthe Mode Functions (IMF) in iterationthat of PEO algorithm According running it each isitknown = 4, the According to to thetherunning result of of thePEO PEOalgorithm, algorithm, is known when that K when K = 4, with different K value in thethe VMD. decomposition results appear abnormal component of permutation entropy value greater the decomposition results appear the abnormal component of permutation entropy valuethan greater the threshold value, while the K = 3 does not appear abnormal components, which indicates that the than the threshold value, the K = 3 does appear abnormal which According to thewhile running result of thenot PEO algorithm, it is components, known that when K indicates = 4, the that K = 4 happens to be over decomposition, so the decomposition mode number K of VMD is three. The appear the abnormal so component of permutation entropy valueKgreater than the K =decomposition 4 happens toresults be over decomposition, the decomposition mode number of VMD is three. number of components in the simulation signal is also exactly three, which is consistent with the the threshold value, while the K = 3 does not appear abnormal components, which indicates that the The number components in the simulation signal is that alsothe exactly three, which consistent with the operationofresults of the PEO algorithm, which shows PEO algorithm can is indeed adaptively K = 4results happens tothe be over decomposition, so theshows decomposition mode number K ofcan VMD is three. The operation of PEO algorithm, which that the PEO algorithm indeed adaptively determine the optimal value of the K. number of components in the simulation signal is also exactly three, which is consistent with the determine the optimal value of the K. operation results of the PEO algorithm, which shows that the PEO algorithm can indeed adaptively 4.3. Parameter setting of MVDM determine the optimal value of the K. 4.3. Parameter setting of MVDM In the MVMD, we need to set the number of cycles N and the white noise amplitude Nstd added. Parameter of MVDM In4.3. the MVMD, we need to the number ofthe cycles N and the white noisenoise. amplitude Nstdthe added. The greater thesetting number of set cycles, the better effect of homogenization However, efficiency of signal processing needs to be taken into account. This paper takes the number of cycles The greater the number of cycles, the better the effect of homogenization noise. However, the efficiency In the MVMD, we need to set the number of cycles N and the white noise amplitude Nstd added. N=100. For thethe selection ofof thecycles, amplitude of positive and of negative Gauss noise, signal of signal needs to be taken intobetter account. This paper takes thewhite number ofthe cycles N to = 100. Theprocessing greater number the the effect homogenization noise. However, the noise ratio (SNR) of reconstructed signal is chosen as the basis for choosing the amplitude of white of signal needs to be taken intonegative account. This paper takesnoise, the number of cycles For theefficiency selection of theprocessing amplitude of positive and Gauss white the signal to noise Through lot of experiments, the experimental results are drawn thenoise, SNR-Nstd diagram N=100. theaselection ofsignal the amplitude ofas positive and negative Gaussinto white theofsignal to noise. rationoise. (SNR) ofFor reconstructed is chosen the basis for choosing the amplitude white asnoise shown in Figure 5. ratio (SNR) of reconstructed signal is chosen as the basis for choosing the amplitude of white Through a lot of experiments, the experimental results are drawn into the SNR-Nstd diagram as shown noise. Through a lot of experiments, the experimental results are drawn into the SNR-Nstd diagram in Figure 5. as shown in Figure 5.

Figure 5. SNR-Nstd (Signal to noise ratio -Noise of the standard deviation of the added) diagram. Figure 5. SNR-Nstd (Signal to noise ratio-Noise -Noise of the deviation of the added) diagram. Figure SNR-Nstd to noise ratio thestandard standard deviation of the diagram. It is 5.known from(Signal the diagram that when theofwhite noise amplitude Nstd isadded) 0.15, the signal to noise ratio of the reconstructed signal is the highest, that is to say, the effect of noise reduction is the It is known from the diagram that when the white noise amplitude Nstd is 0.15, the signal to best. Therefore, for the simulation signal, the amplitude of white noise added in the MVMD is 0.15. noise ratio of the reconstructed signal is the highest, that is to say, the effect of noise reduction is the best. Therefore, for the simulation signal, the amplitude of white noise added in the MVMD is 0.15. 4.4. Comparison of Decomposition Results of Different Algorithms

4.4. Comparison of Decomposition Results of Different Algorithms

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It is known from the diagram that when the white noise amplitude Nstd is 0.15, the signal to noise ratio of the reconstructed signal is the highest, that is to say, the effect of noise reduction is the best. Therefore, for the simulation signal, the amplitude of white noise added in the MVMD is 0.15. Sensors 2018, 18, x FOR PEER REVIEW

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Sensors 2018, 18, x FOR PEER REVIEW 4.4. Comparison of Decomposition

11 of 16 Results of Different Algorithms In order to achieve transversal contrast between different EEMD, VMD, and MVMD are used to In order tosimulation achieve transversal transversal contrastbetween between different EEMD, VMD, MVMD used In order to achieve contrast EEMD, VMD, and MVMD areare used to decompose the signals, respectively. In thedifferent decomposition results ofand EEMD, only the first to decompose the simulation signals, respectively. In the decomposition results of EEMD, only the decompose simulation signals, respectively. the decomposition results of EEMD, only the first four layers the with strong correlation with the In original signal are analyzed. The corresponding first layers with strong correlation with theoriginal original signal are analyzed. analyzed. The The corresponding four four layers with strong correlation with the signal corresponding decomposition results of each algorithm are shown in Figure 6. are decomposition decomposition results results of of each each algorithm algorithm are are shown shown in in Figure Figure 6. 6.

(a) (a)

(b) (b) Figure 6. The spectrum of IMFs after Ensemble Empirical Mode Decomposition (EEMD) and its 6. The ofof IMFs after Ensemble Empirical Mode (EEMD) and and its corresponding spectrum. (a) Time domain of IMFs after EEMD; (b)Decomposition The spectrum corresponding to Figure Thespectrum spectrum IMFs after Ensemble Empirical Mode Decomposition (EEMD) corresponding spectrum. (a) Time domain of IMFs after EEMD; (b) The each layer of IMF. The spectrum spectrum corresponding corresponding to each layer of IMF. IMF.

It can be seen from Figure 6 that there is a serious modal aliasing phenomenon in EEMD It can be be seen seenfrom from Figure 6Hz that a serious aliasing in It can Figure there is a is serious modalmodal aliasing phenomenon in feature EEMD decomposition, and 120 Hz and 630that are,there respectively, decomposed into two phenomenon different EEMD decomposition, and 120 Hz and 30 Hz are, respectively, decomposed into two different decomposition, and 120 Hz and 30 Hz are, respectively, decomposed into two different feature components. feature components. Thecomponents. decomposition results of the VMD is shown in Figure 7, the frequency spectrum of the The decomposition results of the is in frequency of The decomposition results of the VMD VMD is shown shown components in Figure Figure 7, 7, the the frequency spectrum of the the decomposition can be found that low frequency of the 30 Hz spectrum are successfully decomposition bebefound thatthat the low frequency components the affected 30 extracted decomposition canoriginal found the low frequency components of Hz theare 30 Hz are successfully extracted from can the signal, and the frequency spectrum isofless bysuccessfully the noise. However, from original the frequency spectrum is less affected by the noise. However, due to extracted from thesignal, original signal, and the frequency isaliasing less affected byin thethe noise. However, due tothe the interference ofand strong background noise, spectrum the modal occurs 120Hz signal, the interference of strong background noise, the modal aliasing occurs in the 120 Hz signal, which is due to isthe interferenceinto of strong noise, the modal aliasing occurs in signal, which decomposed the twobackground modes of IMF2 and IMF3. The characteristics ofthe the120Hz spectrum are decomposed into the two of IMF2 IMF3.and TheIMF3. characteristics of the spectrum very weak. which is decomposed intomodes the two modesand of IMF2 The characteristics of theare spectrum are very weak. very weak.

(a) (a)

(b) (b)

Figure 7. The spectrum of IMFs after VMD decomposition and its corresponding spectrum. (a) Time The spectrum corresponding to each layer layer of of IMF. IMF. Figure 7.ofThe spectrum of IMFs VMD decomposition and itsto corresponding spectrum. (a) Time domain IMFs after VMD; and after (b) The spectrum corresponding each domain of IMFs after VMD; and (b) The spectrum corresponding to each layer of IMF.

Finally, the decomposition results of the MVMD is shown in Figure 8, it is found that the Finally, the decomposition results of the signal MVMDofisthe shown 8, it is signal found are thatvery the spectrum characteristics of the low frequency 30 HzininFigure the original spectrumbycharacteristics the spectrum low frequency of IMF2, the 30the Hzcentral in the frequency original signal areofvery obvious observing theoftime of the signal IMF1. In 120 Hz the obvious by observing the time spectrum of the IMF1. In IMF2, the central ffrequency 120 f n 2 Hz of the n1 and amplitude modulation signal and the two modulation frequencies are also f n1 fn2 amplitude modulation signal the signal two modulation and band also successfully stripped from the and original with strongfrequencies noise, and the side isare evenly

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Finally, the decomposition results of the MVMD is shown in Figure 8, it is found that the spectrum characteristics of the low frequency signal of the 30 Hz in the original signal are very obvious by observing the time spectrum of the IMF1. In IMF2, the central frequency 120 Hz of the amplitude modulation signal and the two modulation frequencies f n1 and f n2 are also successfully stripped12from Sensors 2018, 18, x FOR PEER REVIEW of 16 the original signal with strong noise, and the side band is evenly distributed on both sides of the main frequency. In IMF3, The center uniform distribution on both sides uniform distribution on both sides frequency of the 10 280 Hz Hz sideand arethe also very obvious. While the noise of the 10 Hz side are also very obvious. While the noise components appear near 500 Hz, the noise components appear near 500 Hz, the noise components are very weak compared to the main components are very weak compared the main frequency components of the 280 Hz,ofwhich has frequency components of the 280 Hz, to which has little influence on the identification the fault little influence on thecompared identification of the 6fault In addition, to Figures 6 andthe 7, features. In addition, to Figures andfeatures. 7, the MVMD can notcompared only effectively eliminate the MVMD can not only effectively eliminate the phenomenon of modal aliasing in VMD, but also phenomenon of modal aliasing in VMD, but also obtain very obvious frequency characteristics in the obtain very frequency characteristics in the strong noise environment. strong noiseobvious environment.

(a)

(b)

Figure 8. The The spectrum spectrum of of IMFs IMFs after after MVMD MVMD decomposition decomposition and and its its corresponding corresponding spectrum. (a) (a) Time Time MVMD; and and (b) (b) The The spectrum spectrum corresponding domain of IMFs after MVMD; corresponding to to each each layer layer of of IMF. IMF.

5. Analysis Analysis of Box 5. ofMeasured MeasuredSignal SignalininGear Gear Box In order to to verify verify the theeffectiveness effectivenessand andfeasibility feasibility MVMD in engineering practice, In order of of thethe MVMD in engineering practice, the the relevant experiments on closed power flow gearbox test rig are carried out in this paper. relevant experiments on closed power flow gearbox test rig are carried out in this paper. The complex The vibration signals of thethe gear box under the condition of normal, surface faultcomplex vibrationfault signals of the gear box under condition of normal, tooth surface pittingtooth and bearing pitting and are bearing outer ring are measured the to MVMD is used process these outer ring measured respectively. Then,respectively. the MVMDThen, is used process thesetocomplex fault complex fault vibration signals, and a good extraction effect is obtained. The effectiveness vibration signals, and a good extraction effect is obtained. The effectiveness and feasibility of and the feasibility method of the proposed method are verified. proposed are verified. In this this experiment, experiment, the the closed closed power power flow flow test test rig rig is is used used to to collect collect the the compound compound fault fault signal signal of of In gearbox. In the experiment, the gear box was loaded by the internal force generated by the torsion bar. gearbox. In the experiment, the gear box was loaded by the internal force generated by the torsion The of gearbox is adjusted controlling the electromagnetic speed regulating asynchronous bar. speed The speed of gearbox is by adjusted by controlling the electromagnetic speed regulating motor, and the regulating range is 120 r/min–1200 r/min. The test rig is shown in Figure 9, the asynchronous motor, and the regulating range is 120 r/min–1200 r/min. The test rig is shownwhere in Figure fault bearing is at the three direction acceleration sensor 1#. 9, where the fault bearing is at the three direction acceleration sensor 1#.

Figure 9. Gearbox test rig. 1—Speed regulating motor; 2—Clutch; 3—Companion gearbox; 4—Rotating speed torsion meter; 5—Torsion bar; 6—Test gear box; 7—Triaxial acceleration sensor 1#; 8—Triaxial Figure 9. Gearbox test rig. 1—Speed regulating motor; 2—Clutch; 3—Companion gearbox; 4— acceleration sensor 2#. Rotating speed torsion meter; 5—Torsion bar; 6—Test gear box; 7—Triaxial acceleration sensor 1#; 8—Triaxial acceleration sensor 2#.

The experimental device mainly includes the speed display, the three direction acceleration sensor YD77SA (sensitivity is 0.01 V/ms22), the test gear, the test bearing 32,212, the motor, the rotating

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The experimental device mainly includes the speed display, the three direction acceleration sensor YD77SA (sensitivity is 0.01 V/ms2 ), the test gear, the test bearing 32,212, the motor, the rotating shaft and so on. The specific experimental parameters are shown Table 5.

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Table 5. Experimental parameters. Table 5. Experimental parameters. transmission ratio transmission ratio engagement system engagement system frequency of samplingFs frequency of samplingFs Sampling point point N N Sampling load troque T load troque T Gear tooth number z Gear tooth number z rotational speed n

1:1 1:1 Half-toothmeshing meshing Half-tooth 8000Hz Hz 8000 2000 2000 1000 1000N· Nm ·m 1818 1200 rpm

fn rotor frequency rotor frequency fn

2020Hz Hz

rotational speed n

Bearing Bearingouter outerring ring fault fault frequency frequency Gear meshing frequency Gear meshing frequency

1200 rpm

160.2Hz Hz 160.2 180 Hz

180 Hz

In order order to ofof thethe above methods, thethe fault typetype of gear box In to verify verifythe thefeasibility feasibilityand andeffectiveness effectiveness above methods, fault of gear in this experiment is set up as multiple faults. The composite fault types include pitting corrosion and box in this experiment is set up as multiple faults. The composite fault types include pitting corrosion outerouter ring ring faultfault of the as shown in Figure 10. 10. and ofbearing, the bearing, as shown in Figure

(a)

(b)

Figure 10. Figure Figure of of gear gear and and bearing bearing outer outer ring ring fault. fault. (a) (a) Gear Gear pitting pitting failure; failure; and and (b) (b) Implantation Implantation of outer ring fault by EDM.

When the the gear gear system system produces produces vibration vibration shock, shock, the the vibration vibration signal signal will will be transmitted transmitted to to the the When shaft first, first, then then the the shaft shaft will will be be transferred transferred to to the the bearing, bearing, and and finally finally transmitted transmitted to to the the gearbox. gearbox. shaft sensor is placed, placed, the location location of of the the sensor sensor should should be be as as close close to to the vibration vibration When the acceleration sensor source as it can reduce the attenuation of the fault characteristics characteristics in the transmission transmission process, process, so so the the best position position of ofthe themeasuring measuringpoint pointshould should bearing seat. Therefore, in experiment, this experiment, best bebe thethe bearing seat. Therefore, in this two two acceleration sensors 1# and 2# are arranged in this experiment, and the two sensors are used acceleration sensors 1# and 2# are arranged in this experiment, and the two sensors are used to to measure vibration signals of three directions X,and Y, and on two bearing seats, respectively. measure thethe vibration signals of three directions of X,ofY, Z onZ two bearing seats, respectively. As As shown in Figure 9, the acceleration sensor arranged thebearing bearingseat seatofofthe thefailure failurebearing, bearing, shown in Figure 9, the acceleration sensor 1#1# is is arranged ononthe and the the acceleration acceleration sensor sensor 2# 2# is arranged arranged on the bearing seat of the normal bearing. The vibration vibration and signal used in this experiment comes from the acceleration sensor 1#. The vibration vibration signal signal of of compound compound fault fault of of gearbox gearbox collected collected by by closed closed power power flow flow test test rig rig is is The shown Figure 11. The units of amplitude is mm/s mm/s2.2 .

(a)

(b)

Figure 11. Time-frequency spectrum of complex fault signal of gear box. (a) Time domain of complex

measure the vibration signals of three directions of X, Y, and Z on two bearing seats, respectively. As shown in Figure 9, the acceleration sensor 1# is arranged on the bearing seat of the failure bearing, and the acceleration sensor 2# is arranged on the bearing seat of the normal bearing. The vibration signal used in this experiment comes from the acceleration sensor 1#. signal of compound fault of gearbox collected by closed power flow test rig 13 isof 15 Sensors The 2018, vibration 18, 3510 shown Figure 11. The units of amplitude is mm/s2.

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Figure11. 11. Time-frequency Time-frequency spectrum ofof gear box. (a) (a) Time domain of complex Figure spectrumof ofcomplex complexfault faultsignal signal gear box. Time domain of complex fault vibration signal; and (b) Spectrum of complex fault vibration signal. fault vibration and (b) Spectrum of complex fault vibration signal. Sensors 2018, 18, x FORsignal; PEER REVIEW 14 of 16

The The time-frequency time-frequency spectrum spectrum of of complex complex fault fault signal signal of of gearbox gearbox shows shows that that due due to to the the influence influence of of strong strong background background noise, the waveform of time domain is chaotic and irregular. In the spectrum, the Hz and and its its two two doubling doubling 720 720 Hz Hz are are appeared, appeared, and and the the fault fault frequency frequency the gear gear meshing meshing frequency frequency360 360Hz of of the the outer outer ring ring does does not not appear, appear, so so the the fault fault signal signal needs needsfurther further decomposition. decomposition. VMD and the MVMD MVMD based based on on PEO PEO will will be be used used to to decompose decompose the the above above complex complex fault fault signals signals respectively. respectively. First, the PEO is used to determine the decomposition level K, and the initial value ofof KK is is setset to to 2. First, the PEO is used to determine the decomposition level K, and the initial value The iteration is iterated andand thethe optimal value of KofisKfound. TheThe optimal value of the K output by the 2. The iteration is iterated optimal value is found. optimal value of the K output by final PEO algorithm is two, so the number of decomposition modes is K = 2. In addition, through a the final PEO algorithm is two, so the number of decomposition modes is K = 2. In addition, through large number of experiments, the amplitude of the white noise added in the MVMD is 0.85, and the a large number of experiments, the amplitude of the white noise added in the MVMD is 0.85, and number number of of cycles cycles is is N N == 100. Secondly, in order contrast, thethe VMD and MVMD willwill be used to decompose the Secondly, in ordertotoform forma alateral lateral contrast, VMD and MVMD be used to decompose above gearbox compound faultfault signals. TheThe twotwo algorithm decomposes thethe fault signal as shown in the above gearbox compound signals. algorithm decomposes fault signal as shown Figures 12 and 13.13. in Figures 12 and

(a)

(b)

Figure 12. 12. The spectrum of IMFs after VMD decomposition and its corresponding corresponding spectrum. spectrum. (a) Time Time Figure domain of IMFs after to to each layer of domain after VMD VMD of ofvibration vibrationsignal; signal;and and(b) (b)The Thespectrum spectrumcorresponding corresponding each layer IMF. of IMF.

(a)

(b)

Figure 13. The spectrum of IMFs after MVMD decomposition and its corresponding spectrum. (a) Time domain of IMFs after MVMD of vibration signal; and (b) The spectrum corresponding to each

(a)

(b)

Figure 12. The spectrum of IMFs after VMD decomposition and its corresponding spectrum. (a) Time Sensors 2018, 18, domain of3510 IMFs after VMD of vibration signal; and (b) The spectrum corresponding to each layer of14 of 15

IMF.

(a)

(b)

Figure spectrumof ofIMFs IMFsafter afterMVMD MVMD decomposition its corresponding spectrum. (a) Figure 13. 13. The The spectrum decomposition andand its corresponding spectrum. (a) Time Time domain of IMFs MVMD of vibration signal; andThe (b)spectrum The spectrum corresponding to each domain of IMFs after after MVMD of vibration signal; and (b) corresponding to each layer layer of IMF. of IMF.

As result of of thethe decomposition of VMD, it isitfound by observing the Asshown shownininFigure Figure1212asasthe the result decomposition of VMD, is found by observing spectrum that that for the faultfault features of the box under the strong background noise, the the spectrum forcomplex the complex features ofgear the gear box under the strong background noise, VMD has ahas poor extraction effect on the and and the two frequency components in the signal all the VMD a poor extraction effect on feature, the feature, the two frequency components in the signal all have serious modal aliasing, which makes this very weak fault feature more difficult to be extracted. This has caused great difficulties in judging the types of faults. For the decomposition results of the MVMD, the fault frequency of the outer ring in the gearbox 160 Hz, the gear fault characteristic frequency 360 Hz and its two frequency doubling 720 Hz are successfully extracted, and the effect is very obvious compared with the VMD.

6. Conclusions VMD requires a preset number of decomposition layers K and is sensitive to background noise. These shortcomings also become a bottleneck in the practical application of the algorithm. Therefore, an improved algorithm based on Variational Mode Decomposition is proposed in this paper. Through the analysis of the simulation signal and the experimental signal of the gear box, the experimental results show that compared with the VMD, the proposed PEO based MVMD has more obvious advantages. It not only overcomes the limitations of the VMD, but also successfully extracts the complex fault features of the gear box under the strong background noise. The validity and feasibility of this method are verified. In the future, the parameters can be intelligently determined to optimize the VMD and improve the decomposition accuracy. Consider optimizing information entropy and fuzzy entropy as the objective function to further optimize VMD. Author Contributions: Data curation, Junyuan Wang; Formal analysis, Wenhua Du; Writing–original draft, Zhijian Wang. Funding: This work is supported by National Natural Science Foundation of China (No. 51705477), Electronic Test and Measurement Laboratory Fund (No. ZDSYSJ2015004) and Shanxi Scholarship Council of China (No. 2016-083). Conflicts of Interest: The authors declare no conflict of interest.

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