Novel Industrial Wireless Sensor Networks for Machine Condition Monitoring and Fault Diagnosis

This paper proposes a novel industrial wireless sensor network (IWSN) for industrial machine condition monitoring and fault diagnosis. In this paper, the induction motor is taken as an example of monitored industrial equipment due to its wide use in industrial processes. Motor stator current and vibration signals aremeasured for further processing and analysis. On-sensor node feature extraction and on-sensor fault diagnosis using neural networks are then investigated to address the tension between the higher system requirements of IWSNs and the resource-constrained characteristics of sensor nodes. A two-step classifier fusion approach using Dempster–Shafer theory is also explored to increase diagnosis result quality. Four motor operating conditions—normal without load, normal with load, loose feet, and mass imbalance—are monitored to evaluate the proposed system. Experimental results show that, compared with raw data transmission, on-sensor fault diagnosis could reduce payload transmission data by 99%, decrease node energy consumption by 97%, and prolong node lifetime from 106 to 150 h, an increase of 43%. The final fault diagnosis results using the proposed classifier fusion approach give a result certainty of at least 97.5%. To leverage the advantages of on-sensor fault diagnosis, another system operating mode is explored, which only transmits the fault diagnosis result when a fault happens or at a fixed interval. For this mode, the node lifetime reaches 73 days if sensor nodes transmit diagnosis results once per hour.