Research on Fault Recognition of Roadheader Based on Multi-Sensor and Multi-Layer Local Projection

The working environment at coal mining faces is harsh, leading to high failure rates and significant maintenance issues with roadheaders. This study explores multi-layer dimensionality reduction of vibration signal features in complex environments to enhance the differentiation of different operational states of a roadheader, thereby achieving fault recognition of key components. Concurrently, reducing dimensionality in manifold spaces positively influences operational state differentiation. Therefore, this paper integrates manifold learning to conduct multi-sensor and multi-layer data mining to enhance the differential phenotypes between faults of key components of the roadheader. Initially, we constructed multiple status-reference sample sets for each sensor individually, forming multiple manifolds at different spatial points, and utilizing locality-preserving projections (LPP) to extract low-dimensional manifold features. Further fusion of low-dimensional features from multiple sensors was used to elevate samples, constructing an enhanced spatial pseudo-manifold. Finally, we used LPP to re-reduce the enhanced sensitive feature set from multiple vibration sensors, establishing a dual-layer sensitive feature enhancement learning model. Conducting fault recognition analysis on experimental vibration signals, using k-nearest neighbors (KNN) to classify the enhanced feature set, we achieved a recognition success rate of 98.75% for samples, proving the method’s feasibility in fault recognition under complex loads.