Frequency-Focused Sound Data Generator for Fault Diagnosis in Industrial Robots

A frequency-focused sound data generator was developed for the in-situ fault sound diagnosis of industrial robot reducers. The sound data generator, based on a conditional generative adversarial network, selects a target frequency range without relying on domain knowledge. A sound dataset of normal and faulty harmonic drive rotations of in-situ industrial robots was collected using an attachable wireless sound sensor. The generated sound data were evaluated based on the fault diagnosis accuracy of a simple classifier trained using the generated data and tested using real data. The proposed method well-defined the frequency feature clusters and produced high-quality data, exhibiting up to 16.0% higher precision score on normal and 13.0% higher accuracy on weak-fault harmonic drive compared to the conventional methods, achieving fault diagnosis accuracy of 95.6% even in situations of fault data comprising only 5% of the normal data.