Semi-Supervised Gearbox Anomaly Detection Under Variable Operating Conditions

Feature distributions shift under variable-speed gearbox operation, which can cause a model trained only on healthy samples to misclassify normal operating changes as anomalies. A semi-supervised anomaly detection method is proposed in this study. Using healthy data, the method first fits speed-dependent trends for the selected time- and frequency-domain statistics, and the deviations from these trends form the statistical residuals. Computed order tracking then converts the vibration signal to the angular domain, where five mechanism features describe meshing energy, harmonic structure, sideband modulation, and order-spectrum entropy. Removing the corresponding healthy speed trends yields the mechanism residuals. Robust Bounded Health-Consistency Weighting (RB-HCW) weights these residuals according to their variability in healthy data before they are fused with the statistical residuals and modeled by Deep Support Vector Data Description (DeepSVDD). The Sequential Bayesian Queue-Based Alarm (SBQA) module then confirms whether abnormal decisions persist across successive windows. Across the four fault types under the two separately modeled load conditions, the proposed method achieved macro-averaged true positive rate (TPR), accuracy (ACC), and F1-score values of 93.31%, 92.58%, and 94.02%, respectively.