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In recent years, predictive maintenance tasks, especially for bearings, have become increasingly important. Solutions for these use cases concentrate on the classification of faults and the estimation of the Remaining Useful Life (RUL). As of today, these solutions suffer from a lack of training samples. In addition, these solutions often require high-frequency accelerometers, incurring significant costs. To overcome these challenges, this research proposes a combined classification and RUL estimation solution based on a Convolutional Neural Network (CNN) and a Long Short-Term Memory (LSTM) network. This solution relies on a hybrid feature extraction approach, making it especially appropriate for low-cost accelerometers with low sampling frequencies. In addition, it uses transfer learning to be suitable for applications with only a few training samples.
The often-occurring short-term orders of manufactured products require a high machine availability. This requirement increases the importance of predictive maintenance solutions for bearings used in machines. There are, among others, hybrid solutions that rely on a physical model. For their usage, knowing the different degradation stages of bearings is essential. This research analyzes the underlying failure mechanisms of these stages theoretically and in a practical example of the well-known FEMTO dataset used for the IEEE PHM 2012 Data Challenge to provide this knowledge. In addition, it shows for which use cases the usage of low-frequency accelerometers is sufficient. The analysis provides that the degradation stages toward the end of the bearing life can also be detected with low-frequency accelerometers. Further, the importance of high-frequency accelerometers to detect bearing faults in early degradation stages is pointed out. These aspects have not been paid attention to by industry and research until now, despite providing a considerable cost-saving potential.