Fault diagnostics and supervised testing : How fault diagnostic tools can be proactive?

The topic of fault detection and diagnostics (FDD) is studied from the perspective of proactive testing. Unlike most research focus in the diagnosis area in which system outputs are analyzed for diagnosis purposes, in this paper the focus is on the other side of the problem: manipulating system inputs for better diagnosis reasoning. In other words, the question of how diagnostic mechanisms can direct system inputs for better diagnosis analysis is addressed here. It is shown how the problem can be formulated as decision making problem coupled with a Bayesian Network based diagnostic mechanism. The developed mechanism is applied to the problem of supervised testing in HVAC systems.

Application of machine learning in fault diagnostics of mechanical systems

A diagnostic method based on Bayesian Networks (probabilistic graphical models) is presented. Unlike conventional diagnostic approaches, in this method instead of focusing on system residuals at one or a few operating points, diagnosis is done by analyzing system behavior patterns over a window of operation. It is shown how this approach can loosen the dependency of diagnostic methods on precise system modeling while maintaining the desired characteristics of fault detection and diagnosis (FDD) tools (fault isolation, robustness, adaptability, and scalability) at a satisfactory level. As an example, the method is applied to fault diagnosis in HVAC systems, an area with considerable modeling and sensor network constraints.

Bearing Fault Diagnostics Using the Spectral Pattern Recognition

In the field of diagnostics of rolling element bearings, the development of sophisticated techniques, such as Spectral Kurtosis and 2nd Order Cyclostationarity, extended the capability of expert users to identify not only the presence, but also the location of the damage in the bearing. Most of the signal-analysis methods, as the ones previously mentioned, result in a spectrum-like diagram that presents line frequencies or peaks in the neighbourhood of some theoretical characteristic frequencies, in case of damage. These frequencies depend only on damage position, bearing geometry and rotational speed. The major improvement in this field would be the development of algorithms with high degree of automation. This paper aims at this important objective, by discussing for the first time how these peaks can draw away from the theoretical expected frequencies as a function of different working conditions, i.e. speed, torque and lubrication. After providing a brief description of the peak-patterns associated with each type of damage, this paper shows the typical magnitudes of the deviations from the theoretical expected frequencies. The last part of the study presents some remarks about increasing the reliability of the automatic algorithm. The research is based on experimental data obtained by using artificially damaged bearings installed in a gearbox.

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.

Tuning second order cyclostationarity parameters for the diagnostics of rolling element bearings

Failures on rolling element bearings usually originate from cracks that are detectable even in their early stage of propogation by properly analyzing vibration signals measured in the proximity of the bearing. Due to micro-slipping in the roller-races contact, damage-induced vibration signals belong to the family of quasi-periodic signals with a strong second order cyclostationary component. Cyclic coherence and its integrated form are widely considered as the most suitable tools for bearing fault diagnostics and their theoretical bases have been already consolidated. This paper presents how to correctly set the parameters of the cyclostationary analysis tool to be implemented in an automatable algorithm. In the first part of the paper some general guidelines are provided for the specific application. These considerations are further verified, applying cyclostationary tools to data collected in an experimental campaign on a specific test-rig.

A data mining approach for fault diagnosis: An application of anomaly detection algorithm

Rolling-element bearing failures are the most frequent problems in rotating machinery, which can be catastrophic and cause major downtime. Hence, providing advance failure warning and precise fault detection in such components are pivotal and cost-effective. The vast majority of past research has focused on signal processing and spectral analysis for fault diagnostics in rotating components. In this study, a data mining approach using a machine learning technique called anomaly detection (AD) is presented. This method employs classification techniques to discriminate between defect examples. Two features, kurtosis and Non-Gaussianity Score (NGS), are extracted to develop anomaly detection algorithms. The performance of the developed algorithms was examined through real data from a test to failure bearing. Finally, the application of anomaly detection is compared with one of the popular methods called Support Vector Machine (SVM) to investigate the sensitivity and accuracy of this approach and its ability to detect the anomalies in early stages.

The Information-analytical System for Diagnostics of Aircraft Navigation Units

The operation of technical processes requires increasingly advanced supervision and fault diagnostics to improve reliability and safety. This paper gives an introduction to the field of fault detection and diagnostics and has short methods classification. Growth of complexity and functional importance of inertial navigation systems leads to high losses at the equipment refusals. The paper is devoted to the INS diagnostics system development, allowing identifying the cause of malfunction. The practical realization of this system concerns a software package, performing a set of multidimensional information analysis. The project consists of three parts: subsystem for analyzing, subsystem for data collection and universal interface for open architecture realization. For a diagnostics improving in small analyzing samples new approaches based on pattern recognition algorithms voting and taking into account correlations between target and input parameters will be applied. The system now is at the development stage.

Fehlersuche im Modell - Modellbasiertes Testen und Debuggen

Kern der vorliegenden Arbeit ist die Erforschung von Methoden, Techniken und Werkzeugen zur Fehlersuche in modellbasierten Softwareentwicklungsprozessen. Hierzu wird zuerst ein von mir mitentwickelter, neuartiger und modellbasierter Softwareentwicklungsprozess, der sogenannte Fujaba Process, vorgestellt. Dieser Prozess wird von Usecase Szenarien getrieben, die durch spezielle Kollaborationsdiagramme formalisiert werden. Auch die weiteren Artefakte des Prozess bishin zur fertigen Applikation werden durch UML Diagrammarten modelliert. Es ist keine Programmierung im Quelltext nötig. Werkzeugunterstützung für den vorgestellte Prozess wird von dem Fujaba CASE Tool bereitgestellt. Große Teile der Werkzeugunterstützung für den Fujaba Process, darunter die Toolunterstützung für das Testen und Debuggen, wurden im Rahmen dieser Arbeit entwickelt. Im ersten Teil der Arbeit wird der Fujaba Process im Detail erklärt und unsere Erfahrungen mit dem Einsatz des Prozesses in Industrieprojekten sowie in der Lehre dargestellt. Der zweite Teil beschreibt die im Rahmen dieser Arbeit entwickelte Testgenerierung, die zu einem wichtigen Teil des Fujaba Process geworden ist. Hierbei werden aus den formalisierten Usecase Szenarien ausführbare Testfälle generiert. Es wird das zugrunde liegende Konzept, die konkrete technische Umsetzung und die Erfahrungen aus der Praxis mit der entwickelten Testgenerierung dargestellt. Der letzte Teil beschäftigt sich mit dem Debuggen im Fujaba Process. Es werden verschiedene im Rahmen dieser Arbeit entwickelte Konzepte und Techniken vorgestellt, die die Fehlersuche während der Applikationsentwicklung vereinfachen. Hierbei wurde darauf geachtet, dass das Debuggen, wie alle anderen Schritte im Fujaba Process, ausschließlich auf Modellebene passiert. Unter anderem werden Techniken zur schrittweisen Ausführung von Modellen, ein Objekt Browser und ein Debugger, der die rückwärtige Ausführung von Programmen erlaubt (back-in-time debugging), vorgestellt. Alle beschriebenen Konzepte wurden in dieser Arbeit als Plugins für die Eclipse Version von Fujaba, Fujaba4Eclipse, implementiert und erprobt. Bei der Implementierung der Plugins wurde auf eine enge Integration mit Fujaba zum einen und mit Eclipse auf der anderen Seite geachtet. Zusammenfassend wird also ein Entwicklungsprozess vorgestellt, die Möglichkeit in diesem mit automatischen Tests Fehler zu identifizieren und diese Fehler dann mittels spezieller Debuggingtechniken im Programm zu lokalisieren und schließlich zu beheben. Dabei läuft der komplette Prozess auf Modellebene ab. Für die Test- und Debuggingtechniken wurden in dieser Arbeit Plugins für Fujaba4Eclipse entwickelt, die den Entwickler bestmöglich bei der zugehörigen Tätigkeit unterstützen.

Reconhecimento de padrões de falhas em motores trifásicos utilizando redes neurais

This work presents a diagnosis faults system (rotor, stator, and contamination) of three-phase induction motor through equivalent circuit parameters and using techniques patterns recognition. The technology fault diagnostics in engines are evolving and becoming increasingly important in the field of electrical machinery. The neural networks have the ability to classify non-linear relationships between signals through the patterns identification of signals related. It is carried out induction motor´s simulations through the program Matlab R & Simulink R , and produced some faults from modifications in the equivalent circuit parameters. A system is implemented with multiples classifying neural network two neural networks to receive these results and, after well-trained, to accomplish the identification of fault´s pattern

The use of fault detection and diagnostics to reduce air handling unit energy consumption

The contribution of buildings towards total worldwide energy consumption in developed countries is between 20% and 40%. Heating Ventilation and Air Conditioning (HVAC), and more specifically Air Handling Units (AHUs) energy consumption accounts on average for 40% of a typical medical device manufacturing or pharmaceutical facility’s energy consumption. Studies have indicated that 20 – 30% energy savings are achievable by recommissioning HVAC systems, and more specifically AHU operations, to rectify faulty operation. Automated Fault Detection and Diagnosis (AFDD) is a process concerned with potentially partially or fully automating the commissioning process through the detection of faults. An expert system is a knowledge-based system, which employs Artificial Intelligence (AI) methods to replicate the knowledge of a human subject matter expert, in a particular field, such as engineering, medicine, finance and marketing, to name a few. This thesis details the research and development work undertaken in the development and testing of a new AFDD expert system for AHUs which can be installed in minimal set up time on a large cross section of AHU types in a building management system vendor neutral manner. Both simulated and extensive field testing was undertaken against a widely available and industry known expert set of rules known as the Air Handling Unit Performance Assessment Rules (APAR) (and a later more developed version known as APAR_extended) in order to prove its effectiveness. Specifically, in tests against a dataset of 52 simulated faults, this new AFDD expert system identified all 52 derived issues whereas the APAR ruleset identified just 10. In tests using actual field data from 5 operating AHUs in 4 manufacturing facilities, the newly developed AFDD expert system for AHUs was shown to identify four individual fault case categories that the APAR method did not, as well as showing improvements made in the area of fault diagnosis.

Bearing fault prognosis based on health state probability estimation

In condition-based maintenance (CBM), effective diagnostic and prognostic tools are essential for maintenance engineers to identify imminent fault and predict the remaining useful life before the components finally fail. This enables remedial actions to be taken in advance and reschedule of production if necessary. All machine components are subjected to degradation processes in real environments and they have certain failure characteristics which can be related to the operating conditions. This paper describes a technique for accurate assessment of the remnant life of bearings based on health state probability estimation and historical knowledge embedded in the closed loop diagnostics and prognostics system. The technique uses the Support Vector Machine (SVM) classifier as a tool for estimating health state probability of machine degradation process to provide long term prediction. To validate the feasibility of the proposed model, real life fault historical data from bearings of High Pressure-Liquefied Natural Gas (HP-LNG) pumps were analysed and used to obtain the optimal prediction of remaining useful life (RUL). The results obtained were very encouraging and showed that the proposed prognosis system based on health state probability estimation has the potential to be used as an estimation tool for remnant life prediction in industrial machinery.

Fault symptoms of rolling element bearings under variable operating conditions - a multi domain analysis

Diagnostics of rolling element bearings have been traditionally developed for constant operating conditions, and sophisticated techniques, like Spectral Kurtosis or Envelope Analysis, have proven their effectiveness by means of experimental tests, mainly conducted in small-scale laboratory test-rigs. Algorithms have been developed for the digital signal processing of data collected at constant speed and bearing load, with a few exceptions, allowing only small fluctuations of these quantities. Owing to the spreading of condition based maintenance in many industrial fields, in the last years a need for more flexible algorithms emerged, asking for compatibility with highly variable operating conditions, such as acceleration/deceleration transients. This paper analyzes the problems related with significant speed and load variability, discussing in detail the effect that they have on bearing damage symptoms, and propose solutions to adapt existing algorithms to cope with this new challenge. In particular, the paper will i) discuss the implication of variable speed on the applicability of diagnostic techniques, ii) address quantitatively the effects of load on the characteristic frequencies of damaged bearings and iii) finally present a new approach for bearing diagnostics in variable conditions, based on envelope analysis. The research is based on experimental data obtained by using artificially damaged bearings installed on a full scale test-rig, equipped with actual train traction system and reproducing the operation on a real track, including all the environmental noise, owing to track irregularity and electrical disturbances of such a harsh application.

The combination of empirical mode decomposition and minimum entropy deconvolution for roller bearing diagnostics in non-stationary operation

Diagnostics is based on the characterization of mechanical system condition and allows early detection of a possible fault. Signal processing is an approach widely used in diagnostics, since it allows directly characterizing the state of the system. Several types of advanced signal processing techniques have been proposed in the last decades and added to more conventional ones. Seldom, these techniques are able to consider non-stationary operations. Diagnostics of roller bearings is not an exception of this framework. In this paper, a new vibration signal processing tool, able to perform roller bearing diagnostics in whatever working condition and noise level, is developed on the basis of two data-adaptive techniques as Empirical Mode Decomposition (EMD), Minimum Entropy Deconvolution (MED), coupled by means of the mathematics related to the Hilbert transform. The effectiveness of the new signal processing tool is proven by means of experimental data measured in a test-rig that employs high power industrial size components.