Nonlinear PCA with Local Approach for Diesel Engine Fault Detection and Diagnosis

This brief examines the application of nonlinear statistical process control to the detection and diagnosis of faults in automotive engines. In this statistical framework, the computed score variables may have a complicated nonparametric distri- bution function, which hampers statistical inference, notably for fault detection and diagnosis. This brief shows that introducing the statistical local approach into nonlinear statistical process control produces statistics that follow a normal distribution, thereby enabling a simple statistical inference for fault detection. Further, for fault diagnosis, this brief introduces a compensation scheme that approximates the fault condition signature. Experimental results from a Volkswagen 1.9-L turbo-charged diesel engine are included.

Application of auto-associative neural networks to transient fault detection in an IC engine

The tailpipe emissions from automotive engines have been subject to steadily reducing legislative limits. This reduction has been achieved through the addition of sub-systems to the basic four-stroke engine which thereby increases its complexity. To ensure the entire system functions correctly, each system and / or sub-systems needs to be continuously monitored for the presence of any faults or malfunctions. This is a requirement detailed within the On-Board Diagnostic (OBD) legislation. To date, a physical model approach has been adopted by me automotive industry for the monitoring requirement of OBD legislation. However, this approach has restrictions from the available knowledge base and computational load required. A neural network technique incorporating Multivariant Statistical Process Control (MSPC) has been proposed as an alternative method of building interrelationships between the measured variables and monitoring the correct operation of the engine. Building upon earlier work for steady state fault detection, this paper details the use of non-linear models based on an Auto-associate Neural Network (ANN) for fault detection under transient engine operation. The theory and use of the technique is shown in this paper with the application to the detection of air leaks within the inlet manifold system of a modern gasoline engine whilst operated on a pseudo-drive cycle. Copyright © 2007 by ASME.

PLS modelling and fault detection on the Tennessee Eastman benchmark

This paper describes the application of multivariate regression techniques to the Tennessee Eastman benchmark process for modelling and fault detection. Two methods are applied : linear partial least squares, and a nonlinear variant of this procedure using a radial basis function inner relation. The performance of the RBF networks is enhanced through the use of a recently developed training algorithm which uses quasi-Newton optimization to ensure an efficient and parsimonious network; details of this algorithm can be found in this paper. The PLS and PLS/RBF methods are then used to create on-line inferential models of delayed process measurements. As these measurements relate to the final product composition, these models suggest that on-line statistical quality control analysis should be possible for this plant. The generation of `soft sensors' for these measurements has the further effect of introducing a redundant element into the system, redundancy which can then be used to generate a fault detection and isolation scheme for these sensors. This is achieved by arranging the sensors and models in a manner comparable to the dedicated estimator scheme of Clarke et al. 1975, IEEE Trans. Pero. Elect. Sys., AES-14R, 465-473. The effectiveness of this scheme is demonstrated on a series of simulated sensor and process faults, with full detection and isolation shown to be possible for sensor malfunctions, and detection feasible in the case of process faults. Suggestions for enhancing the diagnostic capacity in the latter case are covered towards the end of the paper.

Application of Nonlinear PCA for Fault Detection in Polymer Extrusion Processes

This paper describes the application of an improved nonlinear principal component analysis (PCA) to the detection of faults in polymer extrusion processes. Since the processes are complex in nature and nonlinear relationships exist between the recorded variables, an improved nonlinear PCA, which incorporates the radial basis function (RBF) networks and principal curves, is proposed. This algorithm comprises two stages. The first stage involves the use of the serial principal curve to obtain the nonlinear scores and approximated data. The second stage is to construct two RBF networks using a fast recursive algorithm to solve the topology problem in traditional nonlinear PCA. The benefits of this improvement are demonstrated in the practical application to a polymer extrusion process.

Fault Diagnostics for Internal Combustion Engines – Current and Future Techniques

The adoption of each new level of automotive emissions legislation often requires the introduction of additional emissions reduction techniques or the development of existing emissions control systems. This, in turn, usually requires the implementation of new sensors and hardware which must subsequently be monitored by the on-board fault detection systems. The reliable detection and diagnosis of faults in these systems or sensors, which result in the tailpipe emissions rising above the progressively lower failure thresholds, provides enormous challenges for OBD engineers. This paper gives a review of the field of fault detection and diagnostics as used in the automotive industry. Previous work is discussed and particular emphasis is placed on the various strategies and techniques employed. Methodologies such as state estimation, parity equations and parameter estimation are explained with their application within a physical model diagnostic structure. The utilization of symptoms and residuals in the diagnostic process is also discussed. These traditional physical model based diagnostics are investigated in terms of their limitations. The requirements from the OBD legislation are also addressed. Additionally, novel diagnostic techniques, such as principal component analysis (PCA) are also presented as a potential method of achieving the monitoring requirements of current and future OBD legislation.

A statistical process control approach for automatic anti-islanding detection using synchrophasors

Anti-islanding protection is becoming increasingly important due to the rapid installation of distributed generation from renewable resources like wind, tidal and wave, solar PV, bio-fuels, as well as from other resources like diesel. Unintentional islanding presents a potential risk for damaging utility plants and equipment connected from the demand side, as well as to public and personnel in utility plants. This paper investigates automatic islanding detection. This is achieved by deploying a statistical process control approach for fault detection with the real-time data acquired through a wide area measurement system, which is based on Phasor Measurement Unit (PMU) technology. In particular, the principal component analysis (PCA) is used to project the data into principal component subspace and residual space, and two statistics are used to detect the occurrence of fault. Then a fault reconstruction method is used to identify the fault and its development over time. The proposed scheme has been used in a real system and the results have confirmed that the proposed method can correctly identify the fault and islanding site.

Loss-of-Main Monitoring and Detection for Distributed Generations Using Dynamic Principal Component Analysis

In this paper, our previous work on Principal Component Analysis (PCA) based fault detection method is extended to the dynamic monitoring and detection of loss-of-main in power systems using wide-area synchrophasor measurements. In the previous work, a static PCA model was built and verified to be capable of detecting and extracting system faulty events; however the false alarm rate is high. To address this problem, this paper uses a well-known ‘time lag shift’ method to include dynamic behavior of the PCA model based on the synchronized measurements from Phasor Measurement Units (PMU), which is named as the Dynamic Principal Component Analysis (DPCA). Compared with the static PCA approach as well as the traditional passive mechanisms of loss-of-main detection, the proposed DPCA procedure describes how the synchrophasors are linearly
auto- and cross-correlated, based on conducting the singular value decomposition on the augmented time lagged synchrophasor matrix. Similar to the static PCA method, two statistics, namely T2 and Q with confidence limits are calculated to form intuitive charts for engineers or operators to monitor the loss-of-main situation in real time. The effectiveness of the proposed methodology is evaluated on the loss-of-main monitoring of a real system, where the historic data are recorded from PMUs installed in several locations in the UK/Ireland power system.

Feature Selection for Anomaly Detection Using Optical Emission Spectroscopy

To maintain the pace of development set by Moore's law, production processes in semiconductor manufacturing are becoming more and more complex. The development of efficient and interpretable anomaly detection systems is fundamental to keeping production costs low. As the dimension of process monitoring data can become extremely high anomaly detection systems are impacted by the curse of dimensionality, hence dimensionality reduction plays an important role. Classical dimensionality reduction approaches, such as Principal Component Analysis, generally involve transformations that seek to maximize the explained variance. In datasets with several clusters of correlated variables the contributions of isolated variables to explained variance may be insignificant, with the result that they may not be included in the reduced data representation. It is then not possible to detect an anomaly if it is only reflected in such isolated variables. In this paper we present a new dimensionality reduction technique that takes account of such isolated variables and demonstrate how it can be used to build an interpretable and robust anomaly detection system for Optical Emission Spectroscopy data.

Analysis of Extended Partial Least Squares for Monitoring Large-Scale Processes

This paper theoretically analysis the recently proposed "Extended Partial Least Squares" (EPLS) algorithm. After pointing out some conceptual deficiencies, a revised algorithm is introduced that covers the middle ground between Partial Least Squares and Principal Component Analysis. It maximises a covariance criterion between a cause and an effect variable set (partial least squares) and allows a complete reconstruction of the recorded data (principal component analysis). The new and conceptually simpler EPLS algorithm has successfully been applied in detecting and diagnosing various fault conditions, where the original EPLS algorithm did only offer fault detection.

Improved Process Monitoring Using Nonlinear Principal Component Models

This paper presents two new approaches for use in complete process monitoring. The firstconcerns the identification of nonlinear principal component models. This involves the application of linear
principal component analysis (PCA), prior to the identification of a modified autoassociative neural network (AAN) as the required nonlinear PCA (NLPCA) model. The benefits are that (i) the number of the reduced set of linear principal components (PCs) is smaller than the number of recorded process variables, and (ii) the set of PCs is better conditioned as redundant information is removed. The result is a new set of input data for a modified neural representation, referred to as a T2T network. The T2T NLPCA model is then used for complete process monitoring, involving fault detection, identification and isolation. The second approach introduces a new variable reconstruction algorithm, developed from the T2T NLPCA model. Variable reconstruction can enhance the findings of the contribution charts still widely used in industry by reconstructing the outputs from faulty sensors to produce more accurate fault isolation. These ideas are illustrated using recorded industrial data relating to developing cracks in an industrial glass melter process. A comparison of linear and nonlinear models, together with the combined use of contribution charts and variable reconstruction, is presented.