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Journals / Black Sea Journal of Engineering and Science / 2026 / Cilt: 9 Sayı: 5

Predictive Maintenance and Fault Diagnosis Based on Machine Learning with Open Data Set in Brushed DC Motors

Fırçalı DA Motorlarda Açık Veri Seti İle Makine Öğrenmesi Tabanlı Kestirimci Bakım ve Arıza Teşhisi

Erdoğan Özel(VAN YÜZÜNCÜ YIL ÜNİVERSİTESİ MÜHENDİSLİK FAKÜLTESİ)0000-0002-4366-7257
Pages
2454–2462
Publication Date
2026-09-15
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AI Summary & Key Takeaways

AI Insight
⚡ TL;DR(Too Long; Didn't Read)

The results indicate that the proposed approach can be used as a reliable and effective decision support system for condition monitoring and predictive maintenance applications in brushed DC motors.

📌 3 Key Takeaways

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Objective & Hypothesis:Brushed DC motors are widely used in industrial automation systems and drive mechanisms, but brush wear and winding deformations can lead to unexpected shutdowns and high maintenance costs.
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Key Findings & Data:Using current, voltage, speed, motor-ambient temperature difference, and spectral vibration features obtained from multiple sensors in the F.A.I.R dataset, motor life was divided into four health stages: Stage I (Healthy), Stage II (Slight Wear), Stage III (Moderate Wear), and Stage IV (Critical/Failure).
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Conclusion & Impact:The results indicate that the proposed approach can be used as a reliable and effective decision support system for condition monitoring and predictive maintenance applications in brushed DC motors.
🔬Design:Modeling & Simulation
📍Scope:Comprehensive Sample
⚙️Variables:Fırçalı DA motor · Kalan faydalı ömür (RUL) · Durum teşhisi

Abstract

Brushed DC motors are widely used in industrial automation systems and drive mechanisms, but brush wear and winding deformations can lead to unexpected shutdowns and high maintenance costs. This study proposes data-driven, tree-based ensemble learning methods for condition diagnosis and Remaining Useful Life (RUL) estimation of brushed DC motors. Using current, voltage, speed, motor-ambient temperature difference, and spectral vibration features obtained from multiple sensors in the F.A.I.R dataset, motor life was divided into four health stages: Stage I (Healthy), Stage II (Slight Wear), Stage III (Moderate Wear), and Stage IV (Critical/Failure). In condition diagnosis, the Random Forest algorithm showed higher performance than the Extra Trees algorithm with 98.7% test accuracy and 95.70% 10-fold cross-validation success. Feature significance analysis revealed that the variables most strongly representing motor health were net temperature rise, high-frequency vibration components (16–26 kHz), and motor speed. In RUL prediction, the Extra Trees Regressor model achieved the most successful result with a coefficient of determination (R²) of 0.9666 and a time-step RMSE value of 21.49, while the Random Forest Regressor model showed similarly high performance with an R² of 0.9603 and a time-step RMSE value of 23.43. The results indicate that the proposed approach can be used as a reliable and effective decision support system for condition monitoring and predictive maintenance applications in brushed DC motors.

Özet

Fırçalı Doğru Akım (FDA) motorları, endüstriyel otomasyon sistemlerinde ve tahrik mekanizmalarında yaygın olarak kullanılmakta olup, fırça aşınması ve sargı deformasyonları beklenmedik duruşlara ve yüksek bakım maliyetlerine neden olabilmektedir. Bu çalışmada, fırçalı DA motorların durum teşhisi ve Kalan Faydalı Ömür (Remaining Useful Life, RUL) tahmini için veri odaklı, ağaç tabanlı toplu öğrenme yöntemleri önerilmiştir. F.A.I.R veri setinden çoklu sensörlerden elde edilen akım, gerilim, devir, motor-ortam sıcaklık farkı ve spektral titreşim öznitelikleri kullanılarak motor ömrü; Evre I (Sağlıklı), Evre II (Hafif Aşınma), Evre III (Orta Aşınma) ve Evre IV (Kritik/Arıza) olmak üzere dört sağlık evresine ayrılmıştır. Durum teşhisinde Random Forest algoritması %98,7 test doğruluğu ve %95,70 10 katlı çapraz doğrulama başarısı ile Extra Trees algoritmasına göre daha yüksek performans göstermiştir. Öznitelik önem analizi, motor sağlığını en güçlü şekilde temsil eden değişkenlerin net sıcaklık artışı, yüksek frekanslı titreşim bileşenleri (16–26 kHz) ve motor devri olduğunu ortaya koymuştur. RUL tahmininde ise Extra Trees Regressor modeli 0,9666 belirlenme katsayısı (R²) ve 21,49 zaman adımı RMSE değeri ile en başarılı sonucu elde ederken, Random Forest Regressor modeli 0,9603 R² ve 23,43 zaman adımı RMSE değerleriyle benzer düzeyde yüksek performans sergilemiştir. Elde edilen sonuçlar, önerilen yaklaşımın FDA motorlarda durum izleme ve öngörücü bakım uygulamaları için güvenilir ve etkili bir karar destek sistemi olarak kullanılabileceğini göstermektedir.

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Cite This Article

Özel, E. (2026). Predictive Maintenance and Fault Diagnosis Based on Machine Learning with Open Data Set in Brushed DC Motors. Black Sea Journal of Engineering and Science, Cilt: 9 Sayı: 5, 2454–2462. https://doi.org/10.34248/bsengineering.1990452

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