Intelligent Diagnosis Method for Early Weak Faults Based on Wave Intercorrelation–Convolutional Neural Networks

Rolling bearings are widely used in rotating machinery, and their health status is crucial for the safe operation of the equipment. The research on relevant fault diagnosis algorithms is a hot topic in the field. As a leading deep learning paradigm, Convolutional Neural Networks (CNNs) have demonstrated remarkable effectiveness in bearing fault diagnosis. However, conventional CNNs encounter significant limitations in accurately identifying and classifying early-stage bearing faults, primarily due to two challenges: (1) the diagnostic accuracy is highly susceptible to variations in the input signal length and segmentation strategies and (2) incipient faults are characterized by extremely low signal-to-noise ratios (SNRs), which obscure fault signatures. To address these challenges, we propose a Waveform Intersection-CNN (WI-CNN)-based intelligent diagnosis method for early faults. This approach integrates Gramian Angular Field theory to construct high-resolution fault signatures, enabling the CNN-based diagnosis of incipient bearing faults. Validation using the Case Western Reserve University dataset demonstrates an average diagnostic accuracy exceeding 98%. Furthermore, we established a custom test platform to develop a hybrid diagnosis strategy for 10 distinct fault types. Comparative studies against two conventional CNN diagnostic methods confirm that our approach delivers superior diagnostic precision, a faster iteration speed, and enhanced algorithmic robustness. The empirical findings demonstrate that the model achieves an accuracy of 99.67% during training and 98.167% in the testing phase. Crucially, the proposed method offers exceptional simplicity, computational efficiency, and practical applicability, facilitating its widespread implementation.