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Journal of ZheJiang University (Engineering Science)  2026, Vol. 60 Issue (12): 2555-2563    DOI: 10.3785/j.issn.1008-973X.2026.12.001
    
Anomaly detection using wavelet residual network for pump valves via transfer learning under variable operating conditions
Xiao WU1(),Mingxuan ZHANG3,Zhiye HE1,Feng LUO1,Guojin SI1,Tangbin XIA1,2,*()
1. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
2. Special Environment Digital Manufacturing Equipment Technology Innovation Center, Mianyang 621900, China
3. Petromentor Intelligence Safe Technology (Beijing) Limited Company, Beijing 100012, China
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Abstract  

A wavelet residual network-based anomaly detection method for transfer learning under variable operating conditions was proposed to address the insufficient generalization performance of fracturing pump valve anomaly detection caused by dynamically varying operating conditions. A multi-branch residual network incorporating wavelet convolution was constructed to extract discriminative fault features from vibration signals. A multi-branch squeeze-and-excitation attention mechanism was utilized to adaptively recalibrate the channels of key fault features, thereby enhancing feature representation capability. A trainable projected gradient method was adopted to minimize the distribution discrepancy between source and target domains, improving the transfer effectiveness and generalization performance of the model under variable operating conditions. The proposed method was validated using vibration data collected from pump valves of fracturing pumps in a real oilfield environment. The experimental results demonstrated that the proposed method achieved a detection accuracy of 99.51%, outperforming existing state-of-the-art methods by more than 1.73%, and exhibited favorable robustness and generalization capability under variable operating conditions.



Key words: transfer learning      wavelet convolution      residual network      attention mechanism      anomaly detection     
Received: 08 December 2025      Published: 21 October 2026
CLC:  TE 934  
Fund:  国家自然科学基金资助项目(72571173,72401187);上海市自然科学基金资助项目(25ZR1401196);国家重点研发计划资助项目(2022YFF0605700).
Corresponding Authors: Tangbin XIA     E-mail: wu1217@sjtu.edu.cn;xtbxtb@sjtu.edu.cn
Cite this article:

Xiao WU,Mingxuan ZHANG,Zhiye HE,Feng LUO,Guojin SI,Tangbin XIA. Anomaly detection using wavelet residual network for pump valves via transfer learning under variable operating conditions. Journal of ZheJiang University (Engineering Science), 2026, 60(12): 2555-2563.

URL:

https://www.zjujournals.com/eng/10.3785/j.issn.1008-973X.2026.12.001     OR     https://www.zjujournals.com/eng/Y2026/V60/I12/2555


面向变工况迁移学习的泵阀小波残差网络异常检测

针对压裂泵泵阀异常检测中因工况动态变化导致的泛化性不足问题,提出面向变工况迁移学习的泵阀小波残差网络异常检测方法. 构建融入小波卷积的多分支残差网络故障特征提取器,从采集的振动信号中提取关键故障特征. 利用多分支挤压激励注意力机制对关键故障特征通道进行自适应权重校准,增强关键故障特征的表征能力. 采用可训练的投影梯度方法来最小化源域与目标域间的分布差异,优化模型在变工况条件下的迁移效果,增强模型的泛化性能. 使用某油田实际作业现场采集的压裂泵泵阀振动数据进行效果验证,实验结果表明,所提方法的检测准确率可达99.51%,较现有先进模型提升1.73%以上,在变工况条件下具有优异的鲁棒性和泛化性能.


关键词: 迁移学习,  小波卷积,  残差网络,  注意力机制,  异常检测 
Fig.1 Framework of pump valve abnormal detection model for variable-condition transfer learning
Fig.2 Schematic diagram of wavelet residual network structure
Fig.3 Multi-branch extrusion attention mechanism structure
Fig.4 Schematic diagram of SQP2800 five-cylinder fracturing pump and sensor arrangement
变速箱
挡位
发动机转速/
(r·min?1)
类别正常
样本
故障
样本
总计
31700~2000工况1300300600
1或21800~2100工况27373146
11400~1700工况39999198
41200~1500工况49393186
Tab.1 Operating condition parameters and sample distribution of fracturing pump dataset
$ m $$\overline {{\mathrm{Acc}}} $/%$ k $$\overline {{\mathrm{Acc}}} $/%
0.196.12197.85
0.397.45298.92
0.598.51399.51
0.797.62498.46
0.997.05598.38
Tab.2 Effect analysis of parameters $ m $ and $ k $ on average accuracy
模块卷积层核大小
Inception模块卷积层1-11×1
卷积层1-23×3
卷积层1-35×5
残差模块卷积层3×3
Tab.3 Convolution kernel size configuration for each module of wavelet residual network
Fig.5 Comparison of performance metrics for different anomaly detection models
Fig.6 Training loss convergence curves of different methods
Fig.7 T-SNE visualization comparison of different transfer learning methods under working condition 1→4
Fig.8 Comparison of average fault detection accuracy among models under different SNR
模型Acc$\overline {\mathrm{Acc}} $
工况1→1工况1→2工况1→3工况1→4
TL-CWNet92.7991.1092.4992.5992.24
ITL-CWNet95.7996.3095.6596.7096.11
ITL-ICWNet99.0497.1197.7897.6697.90
ITL-ICWMNet99.9099.1599.5499.8599.61
Tab.4 Analysis of impact of different modules on average accuracy of cross-condition transfer %
Fig.9 T-SNE visualization comparison of different ablation modules on anomaly detection performance under working conditions 1→4
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