Stagewise Anomaly Detection for E-Transaxle Quality Monitoring Using Wavelet and STFT Features

This paper presents two interpretable machine-learning frameworks for quality screening of e-transaxle assemblies in electric vehicles: a Stagewise Wavelet Isolation Forest (SWIF) framework and a short-time Fourier transform (STFT)-based diagnostic framework. High-dimensional vibration signals acquired from front and back accelerometers are analyzed across multiple operating stages to capture stage-dependent vibration behavior. In the SWIF framework, signals are decomposed using a five-level Daubechies-4 discrete wavelet transform, and blockwise mean-squared coefficients are extracted from the selected wavelet detail level to obtain compact multiscale features. In the STFT-based framework, dominant-frequency trends are extracted from time-frequency representations and summarized through regression coefficients with respect to instantaneous motor speed. Anomaly detection models are trained using accepted production units under the assumption that only a small fraction of accepted assemblies contain latent defects, and their performance is evaluated using road-tested units with validated quality outcomes. Experiments on production and road-tested e-transaxle units show that both approaches provide interpretable diagnostic information, while SWIF achieves the most favorable balance between defect detection and false-positive control. Compared with the STFT-based method and alternative anomaly detectors, SWIF combined with Isolation Forest yields lower anomaly rates within the Accept population while identifying high-risk units from the Reject population. The stagewise structure further localizes anomalous behavior to specific operating conditions, supporting root-cause analysis and targeted process improvement.