Statistical Degradation Models for Electronics

With increasing presence of electronics in modern systems and in every-day products, their reliability is inextricably dependent on that of their electronics. We develop reliability models for failure-time prediction under small failure-time samples and information on individual degradation history. The development of the model extends the work of Whitmore et al. 1998, to incorporate two new data-structures common to reliability testing. Reliability models traditionally use lifetime information to evaluate the reliability of a device or system. To analyze small failure-time samples within dynamic environments where failure mechanisms are unknown, there is a need for models that make use of auxiliary reliability information. In this thesis we present models suitable for reliability data, where degradation variables are latent and can be tracked by related observable variables we call markers. We provide an engineering justification for our model and develop parametric and predictive inference equations for a data-structure that includes terminal observations of the degradation variable and longitudinal marker measurements. We compare maximum likelihood estimation and prediction results obtained by Whitmore et. al. 1998 and show improvement in inference under small sample sizes. We introduce modeling of variable failure thresholds within the framework of bivariate degradation models and discuss ways of incorporating covariates. In the second part of the thesis we investigate anomaly detection through a Bayesian support vector machine and discuss its place in degradation modeling. We compute posterior class probabilities for time-indexed covariate observations, which we use as measures of degradation. Lastly, we present a multistate model used to model a recurrent event process and failure-times. We compute the expected time to failure using counting process theory and investigate the effect of the event process on the expected failure-time estimates

A Generic Prognostic Framework for Remaining Useful Life Prediction of Complex Engineering Systems

Prognostics and Health Management (PHM) is a general term that encompasses methods used to evaluate system health, predict the onset of failure, and mitigate the risks associated with the degraded behavior. Multitudes of health monitoring techniques facilitating the detection and classification of the onset of failure have been developed for commercial and military applications. PHM system designers are currently focused on developing prognostic techniques and integrating diagnostic/prognostic approaches at the system level. This dissertation introduces a prognostic framework, which integrates several methodologies that are necessary for the general application of PHM to a variety of systems. A method is developed to represent the multidimensional system health status in the form of a scalar quantity called a health indicator. This method is able to indicate the effectiveness of the health indicator in terms of how well or how poorly the health indicator can distinguish healthy and faulty system exemplars. A usefulness criterion was developed which allows the practitioner to evaluate the practicability of using a particular prognostic model along with observed degradation evidence data. The criterion of usefulness is based on comparing the model uncertainty imposed primarily by imperfectness of degradation evidence data against the uncertainty associated with the time-to-failure prediction based on average reliability characteristics of the system. This dissertation identifies the major contributors to prognostic uncertainty and analyzes their effects. Further study of two important contributions resulted in the development of uncertainty management techniques to improve PHM performance. An analysis of uncertainty effects attributed to the random nature of the critical degradation threshold, , was performed. An analysis of uncertainty effects attributed to the presence of unobservable failure mechanisms affecting the system degradation process along with observable failure mechanisms was performed. A method was developed to reduce the effects of uncertainty on a prognostic model. This dissertation provides a method to incorporate prognostic information into optimization techniques aimed at finding an optimal control policy for equipment performing in an uncertain environment

Degradation Modeling and Remaining Useful Life Estimation: From Statistical Signal Processing to Deep Learning Models

Aging critical infrastructures and valuable machineries together with recent catastrophic incidents such as the collapse of Morandi bridge, or the Gulf of Mexico oil spill disaster, call for an urgent quest to design advanced and innovative prognostic solutions, and efficiently incorporate multi-sensor streaming data sources for industrial development. Prognostic health management (PHM) is among the most critical disciplines that employs the advancement of the great interdependency between signal processing and machine learning techniques to form a key enabling technology to cope with maintenance development tasks of complex industrial and safety-critical systems. Recent advancements in predictive analytics have empowered the PHM paradigm to move from the traditional condition-based monitoring solutions and preventive maintenance programs to predictive maintenance to provide an early warning of failure, in several domains ranging from manufacturing and industrial systems to transportation and aerospace. The focus of the PHM is centered on two core dimensions; the first is taking into account the behavior and the evolution over time of a fault once it occurs, while the second one aims at estimating/predicting the remaining useful life (RUL) during which a device can perform its intended function. The first dimension is the degradation that is usually determined by a degradation model derived from measurements of critical parameters of relevance to the system. Developing an accurate model for the degradation process is a primary objective in prognosis and health management. Extensive research has been conducted to develop new theories and methodologies for degradation modeling and to accurately capture the degradation dynamics of a system. However, a unified degradation framework has yet not been developed due to: (i) structural uncertainties in the state dynamics of the system and (ii) the complex nature of the degradation process that is often non-linear and difficult to model statistically. Thus even for a single system, there is no consensus on the best degradation model. In this regard, this thesis tries to bridge this gap by proposing a general model that able to model the true degradation path without having any prior knowledge of the true degradation model of the system. Modeling and analysis of degradation behavior lead us to RUL estimation, which is the second dimension of the PHM and the second part of the thesis. The RUL is the main pillar of preventive maintenance, which is the time a machine is expected to work before requiring repair or replacement. Effective and accurate RUL estimation can avoid catastrophic failures, maximize operational availability, and consequently reduce maintenance costs. The RUL estimation is, therefore, of paramount importance and has gained significant attention for its importance to improve systems health management in complex fields including automotive, nuclear, chemical, and aerospace industries to name but a few. A vast number of researches related to different approaches to the concept of remaining useful life have been proposed, and they can be divided into three broad categories: (i) Physics-based; (ii) Data-driven, and; (iii) Hybrid approaches (multiple-model). Each category has its own limitations and issues, such as, hardly adapt to different prognostic applications, in the first one, and accuracy degradation issues, in the second one, because of the deviation of the learned models from the real behavior of the system. In addition to hardly sustain good generalization. Our thesis belongs to the third category, as it is the most promising category, in particular, the new hybrid models, on basis of two different architectures of deep neural networks, which have great potentials to tackle complex prognostic issues associated with systems with complex and unknown degradation processes

Un cadre holistique de la modélisation de la dégradation pour l’analyse de fiabilité et optimisation de la maintenance de systèmes de sécurité nucléaires

Components of nuclear safety systems are in general highly reliable, which leads to a difficulty in modeling their degradation and failure behaviors due to the limited amount of data available. Besides, the complexity of such modeling task is increased by the fact that these systems are often subject to multiple competing degradation processes and that these can be dependent under certain circumstances, and influenced by a number of external factors (e.g. temperature, stress, mechanical shocks, etc.). In this complicated problem setting, this PhD work aims to develop a holistic framework of models and computational methods for the reliability-based analysis and maintenance optimization of nuclear safety systems taking into account the available knowledge on the systems, degradation and failure behaviors, their dependencies, the external influencing factors and the associated uncertainties.The original scientific contributions of the work are: (1) For single components, we integrate random shocks into multi-state physics models for component reliability analysis, considering general dependencies between the degradation and two types of random shocks. (2) For multi-component systems (with a limited number of components):(a) a piecewise-deterministic Markov process modeling framework is developed to treat degradation dependency in a system whose degradation processes are modeled by physics-based models and multi-state models; (b) epistemic uncertainty due to incomplete or imprecise knowledge is considered and a finite-volume scheme is extended to assess the (fuzzy) system reliability; (c) the mean absolute deviation importance measures are extended for components with multiple dependent competing degradation processes and subject to maintenance; (d) the optimal maintenance policy considering epistemic uncertainty and degradation dependency is derived by combining finite-volume scheme, differential evolution and non-dominated sorting differential evolution; (e) the modeling framework of (a) is extended by including the impacts of random shocks on the dependent degradation processes.(3) For multi-component systems (with a large number of components), a reliability assessment method is proposed considering degradation dependency, by combining binary decision diagrams and Monte Carlo simulation to reduce computational costs.Composants de systèmes de sûreté nucléaire sont en général très fiable, ce qui conduit à une difficulté de modéliser leurs comportements de dégradation et d'échec en raison de la quantité limitée de données disponibles. Par ailleurs, la complexité de cette tâche de modélisation est augmentée par le fait que ces systèmes sont souvent l'objet de multiples processus concurrents de dégradation et que ceux-ci peut être dépendants dans certaines circonstances, et influencé par un certain nombre de facteurs externes (par exemple la température, le stress, les chocs mécaniques, etc.).Dans ce cadre de problème compliqué, ce travail de thèse vise à développer un cadre holistique de modèles et de méthodes de calcul pour l'analyse basée sur la fiabilité et la maintenance d'optimisation des systèmes de sûreté nucléaire en tenant compte des connaissances disponibles sur les systèmes, les comportements de dégradation et de défaillance, de leurs dépendances, les facteurs influençant externes et les incertitudes associées.Les contributions scientifiques originales dans la thèse sont:(1) Pour les composants simples, nous intégrons des chocs aléatoires dans les modèles de physique multi-états pour l'analyse de la fiabilité des composants qui envisagent dépendances générales entre la dégradation et de deux types de chocs aléatoires.(2) Pour les systèmes multi-composants (avec un nombre limité de composants):(a) un cadre de modélisation de processus de Markov déterministes par morceaux est développé pour traiter la dépendance de dégradation dans un système dont les processus de dégradation sont modélisées par des modèles basés sur la physique et des modèles multi-états; (b) l'incertitude épistémique à cause de la connaissance incomplète ou imprécise est considéré et une méthode volumes finis est prolongée pour évaluer la fiabilité (floue) du système; (c) les mesures d'importance de l'écart moyen absolu sont étendues pour les composants avec multiples processus concurrents dépendants de dégradation et soumis à l'entretien; (d) la politique optimale de maintenance compte tenu de l'incertitude épistémique et la dépendance de dégradation est dérivé en combinant schéma volumes finis, évolution différentielle et non-dominée de tri évolution différentielle; (e) le cadre de la modélisation de (a) est étendu en incluant les impacts des chocs aléatoires sur les processus dépendants de dégradation.(3) Pour les systèmes multi-composants (avec un grand nombre de composants), une méthode d'évaluation de la fiabilité est proposé considérant la dépendance dégradation en combinant des diagrammes de décision binaires et simulation de Monte Carlo pour réduire le coût de calcul

A framework development to predict remaining useful life of a gas turbine mechanical component

Power-by-the-hour is a performance based offering for delivering outstanding service to operators of civil aviation aircraft. Operators need to guarantee to minimise downtime, reduce service cost and ensure value for money which requires an innovative advanced technology for predictive maintenance. Predictability, availability and reliability of the engine offers better service for operators, and the need to estimate the expected component failure prior to failure occurrence requires a proactive approach to predict the remaining useful life of components within an assembly. This research offers a framework for component remaining useful life prediction using assembly level data. The thesis presents a critical analysis on literature identifying the Weibull method, statistical technique and data-driven methodology relating to remaining useful life prediction, which are used in this research. The AS-IS practice captures relevant information based on the investigation conducted in the aerospace industry. The analysis of maintenance cycles relates to the examination of high-level events for engine availability, whereby more communications with industry showcase a through-life performance timeline visualisation. Overhaul sequence and activities are presented to gain insights of the timeline visualisation. The thesis covers the framework development and application to gas turbine single stage assembly, repair and replacement of components in single stage assembly, and multiple stage assembly. The framework is demonstrated in aerospace engines and power generation engines. The framework developed enables and supports domain experts to quickly respond to, and prepare for maintenance and on-time delivery of spare parts. The results of the framework show the probability of failure based on a pair of error values using the corresponding Scale and Shape parameters. The probability of failure is transformed into the remaining useful life depicting a typical Weibull distribution. The resulting Weibull curves developed with three scenarios of the case shows there are components renewals, therefore, the remaining useful life of the components are established. The framework is validated and verified through a case study with three scenarios and also through expert judgement

Modelo de apoio à decisão para a manutenção condicionada de equipamentos produtivos

Doctoral Thesis for PhD degree in Industrial and Systems EngineeringIntroduction: This thesis describes a methodology to combine Bayesian control chart and CBM (Condition-Based Maintenance) for developing a new integrated model. In maintenance management, it is a challenging task for decision-maker to conduct an appropriate and accurate decision. Proper and well-performed CBM models are beneficial for maintenance decision making. The integration of Bayesian control chart and CBM is considered as an intelligent model and a suitable strategy for forecasting items failures as well as allow providing an effectiveness maintenance cost. CBM models provides lower inventory costs for spare parts, reduces unplanned outage, and minimize the risk of catastrophic failure, avoiding high penalties associated with losses of production or delays, increasing availability. However, CBM models need new aspects and the integration of new type of information in maintenance modeling that can improve the results. Objective: The thesis aims to develop a new methodology based on Bayesian control chart for predicting failures of item incorporating simultaneously two types of data: key quality control measurement and equipment condition parameters. In other words, the project research questions are directed to give the lower maintenance costs for real process control. Method: The mathematical approach carried out in this study for developing an optimal Condition Based Maintenance policy included the Weibull analysis for verifying the Markov property, Delay time concept used for deterioration modeling and PSO and Monte Carlo simulation. These models are used for finding the upper control limit and the interval monitoring that minimizes the (maintenance) cost function. Result: The main contribution of this thesis is that the proposed model performs better than previous models in which the hypothesis of using simultaneously data about condition equipment parameters and quality control measurements improve the effectiveness of integrated model Bayesian control chart for Condition Based Maintenance.Introdução: Esta tese descreve uma metodologia para combinar Bayesian control chart e CBM (Condition- Based Maintenance) para desenvolver um novo modelo integrado. Na gestão da manutenção, é importante que o decisor possa tomar decisões apropriadas e corretas. Modelos CBM bem concebidos serão muito benéficos nas tomadas de decisão sobre manutenção. A integração dos gráficos de controlo Bayesian e CBM é considerada um modelo inteligente e uma estratégica adequada para prever as falhas de componentes bem como produzir um controlo de custos de manutenção. Os modelos CBM conseguem definir custos de inventário mais baixos para as partes de substituição, reduzem interrupções não planeadas e minimizam o risco de falhas catastróficas, evitando elevadas penalizações associadas a perdas de produção ou atrasos, aumentando a disponibilidade. Contudo, os modelos CBM precisam de alterações e a integração de novos tipos de informação na modelação de manutenção que permitam melhorar os resultados.Objetivos: Esta tese pretende desenvolver uma nova metodologia baseada Bayesian control chart para prever as falhas de partes, incorporando dois tipos de dados: medições-chave de controlo de qualidade e parâmetros de condição do equipamento. Por outras palavras, as questões de investigação são direcionadas para diminuir custos de manutenção no processo de controlo.Métodos: Os modelos matemáticos implementados neste estudo para desenvolver uma política ótima de CBM incluíram a análise de Weibull para verificação da propriedade de Markov, conceito de atraso de tempo para a modelação da deterioração, PSO e simulação de Monte Carlo. Estes modelos são usados para encontrar o limite superior de controlo e o intervalo de monotorização para minimizar a função de custos de manutenção.Resultados: A principal contribuição desta tese é que o modelo proposto melhora os resultados dos modelos anteriores, baseando-se na hipótese de que, usando simultaneamente dados dos parâmetros dos equipamentos e medições de controlo de qualidade. Assim obtém-se uma melhoria a eficácia do modelo integrado de Bayesian control chart para a manutenção condicionada

Resilience-enhanced control reconfiguration for autonomous systems

Unmanned systems keep replacing manned systems as a paradigm shift. According to the Unmanned Autonomous Systems (UAS) market forecast reports, the UAS market value is expected to grow two to three times higher in ten years. Considering the economic impacts of UAS application in job markets and component manufacturing industries, the UAS market value may very well exceed, which is predicted in the reports. However, regulations have limited the effective utilization of UAS due to safety concerns. These restrictive regulations significantly delay the potential usefulness of civilian and commercial UAVs. According to the Unmanned Aerial Vehicle (UAV) incidence reports, mechanical failures come out to be one of the top reasons for the incidents except for human errors. Technically, it is impossible to avoid any fault or failure in any systems. However, it can be possible to save the faulty system if the faults are treated properly. In this regard, this research has reviewed the state-of-the-art techniques regarding system safety improvement in the presence of a critical fault mode. Promising concepts are resilience engineering and Active Fault Tolerant Control (AFTCS) systems. Resilience engineering has been more focus on system design and resilience assessment methods. AFTCS mainly contributes to the fast and stable operating point recovery without the consideration of long-term system performances or mission success. Prognostics-enhanced reconfigurable control frameworks have proposed the online prognosis for a Remaining Useful Life (RUL) prediction within the control scheme but do not address comprehensive mission capability trade-offs. The objective of this study is to design a resilience-enhanced reconfigurable control framework for unmanned autonomous systems in the presence of a critical fault mode during the operation. The proposed resilience-enhanced reconfigurable control framework is composed of three fundamental modules: 1) immediate performance recovery by Model Predictive Control (MPC) and Differential Dynamic Programming (DDP) approaches, 2) long-term mission capability trade-offs by an optimization routine, and 3) situational awareness by a particle filtering-based fault diagnosis and Case-Based Reasoning (CBR). Critical development of this thesis is an introduction of an adaptation parameter in an MPC formulation (Module 1) and optimization process to find an optimal value for the adaptation parameter (Module 2). Module 3 enables long-term mission capability reasoning when a new fault growth pattern is observed. In order to test the efficacy of the proposed framework, under-actuated hovercraft as a testbed and an insulation degradation of an electrical thrust motor as a critical fault mode are introduced. The experiments explore the effect of the adaptation parameter on long-term mission capabilities and identify the necessity of the proper trade-offs. Further experiments investigate the efficacy of each module and the integrated framework. The experiment results show that the adaptation parameter adjusts a control strategy, so that mission capabilities are optimized while vulnerable long-term mission capabilities are recovered. The integrated framework presents the improvement to the probability of mission success in the presence of a critical fault mode. Lastly, as a generalization of the design process for the resilience-enhanced reconfigurable control framework, a design methodology suggests a step-by-step design procedure. Assumptions of the research have guided the required steps and limitations of the proposed framework.Ph.D

Modelling polymer electrolyte membrane fuel cells for dynamic reliability assessment

Tackling climate change is arguably the biggest challenge humanity faces in the 21st century. Rising average global temperatures threaten to destabilize the fragile ecosystem of the Earth and bring unprecedented changes to human lives if nothing is done to prevent it. This phenomenon is caused by the anthropogenic greenhouse effect due to the increasing atmospheric concentrations of carbon dioxide (CO2). One way to avert the disaster is to drastically reduce the consumption of fossil fuels in all spheres of human activities, including transportation. To do this, research and development of electric vehicles (EVs) to make them more efficient, reliable and accessible is essential. [Continues.

Safety and Reliability - Safe Societies in a Changing World

The contributions cover a wide range of methodologies and application areas for safety and reliability that contribute to safe societies in a changing world. These methodologies and applications include: - foundations of risk and reliability assessment and management - mathematical methods in reliability and safety - risk assessment - risk management - system reliability - uncertainty analysis - digitalization and big data - prognostics and system health management - occupational safety - accident and incident modeling - maintenance modeling and applications - simulation for safety and reliability analysis - dynamic risk and barrier management - organizational factors and safety culture - human factors and human reliability - resilience engineering - structural reliability - natural hazards - security - economic analysis in risk managemen