A Cross-Machine Intelligent Fault Diagnosis Method with Small and Imbalanced Data Based on the ResFCN Deep Transfer Learning Model

Juanru Zhao, Mei Yuan, Yiwen Cui, Jin Cui

Intelligent fault diagnosis (IFD) for mechanical equipment based on small and imbalanced datasets has been widely studied in recent years, with transfer learning emerging as one of the most promising approaches. Existing transfer learning-based IFD methods typically use data from different operating conditions of the same equipment as the source and target domains for the transfer learning process. However, in practice, it is often challenging to find identical equipment to obtain source domain data when diagnosing faults in the target equipment. These strict assumptions pose significant limitations on the application of IFD techniques in real-world industrial settings. Furthermore, the temporal characteristics of time-series monitoring data are often inadequately considered in existing methods. In this paper, we propose a cross-machine IFD method based on a residual full convolutional neural network (ResFCN) transfer learning model, which leverages the time-series features of monitoring data. By incorporating sliding window (SW)-based data segmentation, network pretraining, and model fine-tuning, the proposed method effectively exploits fault-associated general features in the source domain and learns domain-specific patterns that better align with the target domain, ultimately achieving accurate fault diagnosis for the target equipment. We design and implement three sets of experiments using two widely used public datasets. The results demonstrate that the proposed method outperforms existing approaches in terms of fault diagnosis accuracy and robustness.