DEVELOPMENT OF NOISE AND VIBRATION BASED FAULT DIAGNOSIS METHOD FOR ELECTRIFIED POWERTRAIN USING SUPERVISED MACHINE LEARNING CLASSIFICATION

The industry's interest in electrified powertrain-equipped vehicles has increased due to environmental and economic reasons. Electrified powertrains, in general, produce lower sound and vibration level than those equipped with internal combustion engines, making noise and vibration (N&V) from other non-engine powertrain components more perceptible. One such N&V type that arouses concern to both vehicle manufacturers and passengers is gear growl, but the signal characteristics of gear growl noise and vibration and the threshold of those characteristics that can be used to determine whether a gear growl requires attention are not yet well understood. This study focuses on developing a method to detect gear-growl based on the N\&V measurements and determining thresholds on various severities of gear-growl using supervised machine learning classification. In general, a machine learning classifier requires sufficient high-quality training data with strong information independence to ensure accurate classification performance. In industrial practices, acquiring high-quality vehicle NVH data is expensive in terms of finance, time, and effort. A physically informed data augmentation method is, thus, proposed to generate realistic powertrain NVH signals based on high-quality measurements which not only provides a larger training data set but also enriches the signal feature variations included in the data set. More specifically, this method extracts physical information such as angular speed, tonal amplitudes distribution, and broadband spectrum shape from the measurement data. Then, it recreates a synthetic signal that mimics the measurement data. The measured and simulated (via data augmentation) are transformed into feature matrix representation so that the N\&V signals can be used in the classification model training process. Features describing signal characteristics are studied, extracted, and selected. While the root-mean-square (RMS) of the vibration signal and spectral entropy were sufficient for detecting gear-growl with a test accuracy of 0.9828, the acoustic signal required more features due to background noise, making data linearly inseparable. The minimum Redundancy Maximum Relevance (mRMR) feature scoring method was used to assess the importance of acoustic signal features in classification. The five most important features based on the importance score were the angular acceleration of the driveshaft, the time derivative of RMS, the tone-to-noise ratio (TNR), the time derivative of the spectral spread of the tonal component of the acoustic signal, and the time derivative of the spectral spread of the original acoustic signal (before tonal and broadband separation). A supervised classification model is developed using a support vector machine from the extracted acoustic signal features. Data used in training and testing consists of steady-state vehicle operations of 25, 35, 45, and 55 mph, with two vehicles with two different powertrain specs: axles with 4.56 and 6.14 gear ratios. The dataset includes powertrains with swapped axles (four different configurations). Techniques such as cost weighting, median filter, and hyperparameter tuning are implemented to improve the classification performance where the model classifies if a segment in the signal represents a gear-growl event or no gear-growl event. The average accuracy of test data was 0.918. A multi-class classification model is further implemented to classify different severities based on preliminary subjective listening studies. Data augmentation using signal simulation showed improvement in binary classification applications. In this study, only gear-growl was used as a fault type. Still, data augmentation, feature extraction and selection, and classification methods can be generalized for NVH signal-based fault diagnosis applications. Further listening studies are suggested for improved classification of multi-class classification applications.