轻量化转向架轴承机理仿真辅助下小样本跨域故障诊断
FEW-SHOT CROSS-DOMAIN FAULT DIAGNOSIS ASSISTED BY MECHANISM SIMULATION OF LIGHTWEIGHT BOGIE BEARINGS
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摘要: 轻量化转向架是实现高速列车“减重节能、提质增效”的核心技术, 但轻量化设计改变了轴箱轴承动力学环境, 导致其故障特征更加复杂隐蔽, 现场数据稀缺又进一步制约了轴箱轴承智能运维的发展. 为此, 本文提出一种轻量化转向架轴承机理仿真辅助下小样本跨域故障诊断方法. 首先, 建立了基于碳纤维复合材料(carbon fibre reinforced plastics, CFRP)侧梁的轻量化转向架刚柔耦合动力学模型, 在考虑各部件对轴承动态载荷基础上, 开展了转向架−轴箱轴承联合仿真分析, 构建了含典型故障的轴承仿真数据集. 其次, 搭建了融合VMamba与交叉可变形Transformer(VMamba and cross deformable transformer, VMCDT)的协同模型, 结合教师−学生网络知识蒸馏框架, 实现了跨域复杂特征的深入挖掘与平滑迁移. 最后, 引入标签平滑策略, 实现了跨域场景下轴承小样本故障诊断. 6种不同测试任务的实验结果表明, 所提方法在4-way 1-shot和5-shot下故障诊断准确率达89%和93%以上, 优于传统的小样本学习方法. 该方法突破了仿真−实测数据分布差异大与小样本跨域诊断难度高的双重瓶颈, 为高速列车轻量化转向架−轴箱轴承故障诊断提供了新的范式.Abstract: The lightweight bogie is a core technology for achieving “weight reduction, energy conservation, quality improvement, and efficiency enhancement” in high-speed trains. However, the lightweight design alters the dynamic environment of the axlebox bearings, resulting in more complex and concealed fault characteristics. The scarcity of on-site data further restricts the development of intelligent maintenance for axlebox bearings. To address this, this paper proposes a few-shot cross-domain fault diagnosis method assisted by lightweight bogie bearing mechanism simulation. Firstly, a rigid-flexible coupling dynamic model of a lightweight bogie with carbon fiber reinforced plastics (CFRP) side beams is established. Considering the dynamic loads on the bearings from various components, a joint simulation analysis of the bogie-axlebox bearing is conducted to construct a bearing simulation dataset containing typical faults. Secondly, a collaborative model integrating VMamba and cross deformable transformer (VMCDT) is constructed, combined with a teacher-student network knowledge distillation framework, to achieve in-depth mining and smooth transfer of complex cross-domain features. Finally, by introducing a label smoothing strategy, few-shot fault diagnosis of bearings in cross-domain scenarios is realized. Experimental results from six different testing tasks demonstrate that the proposed method achieves fault diagnosis accuracies exceeding 89% and 93% under 4-way 1-shot and 5-shot conditions, respectively, outperforming conventional few-shot learning approaches. This approach overcomes the dual challenges of significant distribution differences between simulation and measured data and the high difficulty of few-shot cross-domain diagnosis, providing a new paradigm for fault diagnosis of axlebox bearings in lightweight bogies of high-speed trains.
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