Performance analysis of genetically optimized 1D-convolutional neural network architecture for rotor system fault detection and diagnosis

Rotor mass imbalance is a critical problem in industries, which can lead to a breakdown or a catastrophic failure if unattended. Hence, Industry 4.0 uses deep learning approaches like convolutional neural network (CNN) for rotor fault detection and diagnosis of Industrial machines and turbomachinery where multifunctional structures are used. In machinery fault diagnosis, manual tuning of CNN hyperparameters is widely used, which is a tedious, time-consuming, and challenging task to achieve effective feature extraction. Additionally, overfitting of CNN during its training is an obstacle to achieving higher prediction accuracy. Hence, to address these issues, this research focuses on multi-class mass imbalance fault diagnosis using genetically optimized deep learning architecture of 1D-CNN to achieve higher diagnosis capability. The performance of the proposed methodology is evaluated through various case studies using experimental data from the in-house developed test rig. The test results are compared against various 1D-CNN architectures in which the hyperparameters and effective dropout layer positioning are genetically optimized. Also, the performance is benchmarked against standard machine learning algorithms. The results show that genetic algorithm (GA)-optimized 1D-CNN with dropout achieves highest fault prediction accuracy of 97.47% with reduced depth of CNN (with three convolution layers) compared to 84.16% of manually tunned CNN architecture (with seven convolutional layers) and outperformed standard machine learning algorithms. Best drop positioning (end of feature extraction part) reduced the learnable parameters to 95.9% with the highest prediction accuracy of 97.47% compared to adding dropout at all the CNN layers. The proposed GA-optimized 1D-CNN with effective dropout positioning eliminates human intervention and reduces the depth of CNN architecture; this, in turn, reduces computational load and time by reducing learnable parameters of CNN (network weights) with the highest prediction accuracy. Hence, the proposed approach shows promise in enhancing the performance and contributing to the advancement of 1D-CNN for rotor system fault detection and diagnosis.