In fault diagnosis research, compound faults are often regarded as an isolated fault mode, while the association between compound faults and single faults is ignored, resulting in the inability to make accurate and effective diagnoses of compound faults in the absence of compound fault training data. In an examination of the rotate vector (RV) reducer, a core component of industrial robots, this paper proposes a compound fault identification method that is based on an improved convolutional capsule network for compound fault diagnosis of RV reducers. First, one-dimensional convolutional neural networks are used as feature learners to deeply mine the feature information of a single fault from a one-dimensional time-domain signal. Then, a capsule network with a two-layer stack structure is designed and a dynamic routing algorithm is used to decouple and identify the single fault characteristics for compound faults to undertake the diagnosis of compound faults of RV reducers. The proposed method is verified on the RV reducer fault simulation experimental bench, the experimental results show that the method can not only diagnose a single fault, but it is also possible to diagnose the compound fault that is composed of two types of single faults through the learning of two types of single faults of the RV reducer when the training data of the compound faults of the RV reducer are missing. At the same time, the proposed method is used for compound fault diagnosis of bearings, and the experimental results confirm its applicability.

As a core component of industrial robots, the RV reducer directly affects the normal operation of the robot, so it is of great significance to monitor its status and diagnose faults. In the field of fault diagnosis, intelligent diagnosis methods based on deep learning have shown great advantages in accuracy and efficiency. However, as the network depth and scale increase, the exponentially growing model computation and parameter amounts require higher hardware requirements for computers, making it difficult to deploy on embedded platforms with limited computing resources. This makes it difficult for deep learning-based fault diagnosis methods to be applied in practical industrial settings that emphasize real-time performance, portability, and accuracy. This paper proposes a network lightweight method based on knowledge distillation. Using the two-dimensional time-frequency map of vibration signals as the model input, the improved MobileNet-V3 network is used as the teacher network, and the simplified CNN network is used as the student network. The method of knowledge distillation is applied to condense the knowledge and transfer it to the student network. The proposed method is validated using an RV reducer fault simulation experiment platform, and the results show that the proposed method reduces computation and parameter amounts by about 170 times at an accuracy rate of 94.37%, and run time is shortened by nearly one-third, and a generalization verification was conducted using the rotating mechanical fault simulation experiment platform. The models were also deployed on embedded devices to verify that the method proposed in this paper effectively reduces the deep learning network model's demand for hardware resources of the operating environment. This provides an effective reference for deploying and implementing deep learning-based fault diagnosis on embedded systems with lower hardware configurations.