arXiv:2512.19280cs.LGcs.AI2025-12被引 2

用数字孪生生成故障数据,实现零样本泵故障诊断

Digital Twin-Driven Zero-Shot Fault Diagnosis of Axial Piston Pumps Using Fluid-Borne Noise Signals

  • 仅用健康数据校准数字孪生,生成合成故障信号训练模型
  • 真实测试中诊断准确率超95%,未校准模型性能显著下降
  • 结合梯度可视化揭示物理特征的重要性,适合工业场景应用

轴向柱塞泵是流体动力系统中的关键部件,可靠故障诊断对保障运行安全与效率至关重要。传统数据驱动方法需大量标注故障数据,往往难以获取;基于模型的方法则受参数不确定性影响。本文提出一种基于数字孪生(DT)的零样本故障诊断框架,利用流体传播噪声(FBN)信号。该框架仅用健康状态数据校准高保真数字孪生模型,生成合成故障信号用于深度学习分类器训练,并采用物理信息神经网络(PINN)作为虚拟传感器估计流量脉动。通过梯度加权类激活映射(Grad-CAM)可视化神经网络决策过程,发现时间域输入中大卷积核匹配子序列长度、时频域输入中小卷积核能更聚焦于物理有意义特征,从而提升诊断准确率。实验验证表明,使用校准后数字孪生模型生成的信号训练,可在真实基准上实现超过95%的诊断准确率,而未校准模型性能明显降低,凸显该框架在数据稀缺场景下的有效性。

原文摘要 · Abstract (English)

Axial piston pumps are crucial components in fluid power systems, where reliable fault diagnosis is essential for ensuring operational safety and efficiency. Traditional data-driven methods require extensive labeled fault data, which is often impractical to obtain, while model-based approaches suffer from parameter uncertainties. This paper proposes a digital twin (DT)-driven zero-shot fault diagnosis framework utilizing fluid-borne noise (FBN) signals. The framework calibrates a high-fidelity DT model using only healthy-state data, generates synthetic fault signals for training deep learning classifiers, and employs a physics-informed neural network (PINN) as a virtual sensor for flow ripple estimation. Gradient-weighted class activation mapping (Grad-CAM) is integrated to visualize the decision-making process of neural networks, revealing that large kernels matching the subsequence length in time-domain inputs and small kernels in time-frequency domain inputs enable higher diagnostic accuracy by focusing on physically meaningful features. Experimental validations demonstrate that training on signals from the calibrated DT model yields diagnostic accuracies exceeding 95\% on real-world benchmarks, while uncalibrated models result in significantly lower performance, highlighting the framework's effectiveness in data-scarce scenarios.

故障诊断数字孪生零样本学习流体噪声

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