Research on a Fault Diagnosis Method for Rolling Bearings Based on the Fusion of PSR-CRP and DenseNet

To address the challenges of unstable vibration signals, indistinct fault features, and difficulties in feature extraction during rolling bearing operation, this paper presents a novel fault diagnosis method based on the fusion of PSR-CRP and DenseNet. The Phase Space Reconstruction (PSR) method transforms one-dimensional bearing vibration data into a three-dimensional space. Euclidean distances between phase points are calculated and mapped into a Color Recurrence Plot (CRP) to represent the bearings’ operational state. This approach effectively reduces feature extraction ambiguity compared to RP, GAF, and MTF methods. Fault features are extracted and classified using DenseNet’s densely connected topology. Compared with CNN and ViT models, DenseNet improves diagnostic accuracy by reusing limited features across multiple dimensions. The training set accuracy was 99.82% and 99.90%, while the test set accuracy is 97.03% and 95.08% for the CWRU and JNU datasets under five-fold cross-validation; F1 scores were 0.9739 and 0.9537, respectively. This method achieves highly accurate diagnosis under conditions of non-smooth signals and inconspicuous fault characteristics and is applicable to fault diagnosis scenarios for precision components in aerospace, military systems, robotics, and related fields.