Prediction of air compressor faults with feature fusion and machine learning

Air compressors are critical for many industries, but early detection of faults is crucial for keeping them running smoothly and minimizing maintenance costs. This contribution investigates the use of predictive machine learning models and feature fusion to diagnose faults in single-acting, single-stage reciprocating air compressors. Vibration signals acquired under healthy and different faulty conditions (inlet valve fluttering, outlet valve fluttering, inlet-outlet valve fluttering, and check valve fault) serve as the study’s input data. Diverse features including statistical attributes, histogram data, and auto-regressive moving average (ARMA) coefficients are extracted from the vibration signals. To identify the most relevant features, the J48 decision tree algorithm is employed. Five lazy classifiers viz. k-nearest neighbor (kNN), K-star, local kNN, locally weighted learning (LWL), and random subspace ensemble K-nearest neighbors (RseslibKnn) are then used for fault classification, each applied to the individual feature sets. The classifiers achieve commendable accuracy, ranging from 85.33% (K-star and local kNN) to 96.00% (RseslibKnn) for individual features. However, the true innovation lies in feature fusion. Combining the three feature types, statistical, histogram, and ARMA, significantly improves accuracy. When local kNN is used with fused features, the model achieves a remarkable 100% classification accuracy, demonstrating the effectiveness of this approach for reliable fault diagnosis in air compressors. • Diagnosis of air compressor faults using vibration signals. • Extraction of statistical, histogram and ARMA features. • J48 decision tree algorithm for feature selection. • Accuracy up to 96% for lazy classifiers on statistical, histogram or ARMA features. • Feature fusion (Statistical+Histogram+ARMA) achieved 100% classification accuracy.