Semi-Supervised Learning for Diagnosing Faults in Electromechanical Systems

Safe and reliable operation of the systems relies on the use of online condition monitoring and diagnostic systems that aim to take immediate actions upon the occurrence of a fault. Machine learning techniques are widely used for designing data-driven diagnostic models. The training procedure of a data-driven model usually requires a large amount of labeled data, which may not be always practical. This problem can be untangled by resorting to semi-supervised learning approaches, which enables the decision making procedure using only a few numbers of labeled samples coupled with a large number of unlabeled samples. Thus, it is crucial to conduct a critical study on the use of semi-supervised learning for the purpose of fault diagnosis. Another issue of concern is fault diagnosis in non-stationary environments, where data streams evolve over time, and as a result, model-based and most of the data-driven models are impractical. In this work, this has been addressed by means of an adaptive data-driven diagnostic model

Distributed synchronous diagnosis of discrete-event systems

Recently, the centralized and decentralized synchronous diagnosis of discreteevent systems have been proposed in the literature. In this work, we propose a di erent synchronous diagnosis strategy called distributed synchronous diagnosis. In this scheme, local diagnosers are computed based on the observation of the fault-free behavior models of the system components. It is considered that these local diagnosers are separated into networks, and are capable of communicating the occurrence of events and their current state estimate to other local diagnosers that belong to the same network. The diagnosers are implemented considering an speci c communication protocol that re nes the state estimate of the faultfree behavior of the system modules, reducing, therefore, the augmented fault-free language considered for synchronous diagnosis. In order to do so, boolean conditions are added to the transitions of the fault-free component models, which check if the occurrence of an observable event is possible according to the current state estimate of other local diagnosers. This leads to the notion of distributed synchronous diagnosability. An algorithm to verify the distributed synchronous diagnosability with polynomial complexity in the state-space of the system component models is proposed.Recentemente, o diagnóstico síncrono centralizado e descentralizado de sistemas a eventos discretos foi proposto na literatura. Neste trabalho, propomos uma estratégia de diagnóstico síncrono diferente, denominada diagnóstico síncrono distribuído. Neste esquema, diagnosticadores locais são construídos com base na observação do comportamento livre de falha dos componentes do sistema. Considera-se que esses diagnosticadores locais são agrupados em redes de comunicação e capazes de informar a ocorrência de eventos e sua estimativa de estado atual a outros diagnosticadores locais pertencentes à mesma rede. Os diagnosticadores são implementados considerando um protocolo de comunicação específico, o qual refina a estimativa de estado do comportamento livre de falha dos módulos do sistema, reduzindo, portanto, a linguagem aumentada livre de falha considerada no diagnóstico síncrono. Isso é feito com a adição de condições booleanas para a transposição de transições dos modelos livre de falha dos componentes do sistema, as quais verificam se a ocorrência de um evento observável é possível de acordo com a estimativa do estado atual dos outros diagnosticadores locais. Isso leva à noção de diagnosticabilidade síncrona distribuída. Um algoritmo para verificar a diagnosticabilidade síncrona distribuída com complexidade polinomial no espaço de estados dos modelos dos componentes do sistema é proposto

Predictive maintenance: a novel framework for a data-driven, semi-supervised, and partially online prognostic health management application in industries

Prognostic Health Management (PHM) is a predictive maintenance strategy, which is based on Condition Monitoring (CM) data and aims to predict the future states of machinery. The existing literature reports the PHM at two levels: methodological and applicative. From the methodological point of view, there are many publications and standards of a PHM system design. From the applicative point of view, many papers address the improvement of techniques adopted for realizing PHM tasks without covering the whole process. In these cases, most applications rely on a large amount of historical data to train models for diagnostic and prognostic purposes. Industries, very often, are not able to obtain these data. Thus, the most adopted approaches, based on batch and off-line analysis, cannot be adopted. In this paper, we present a novel framework and architecture that support the initial application of PHM from the machinery producers’ perspective. The proposed framework is based on an edge-cloud infrastructure that allows performing streaming analysis at the edge to reduce the quantity of the data to store in permanent memory, to know the health status of the machinery at any point in time, and to discover novel and anomalous behaviors. The collection of the data from multiple machines into a cloud server allows training more accurate diagnostic and prognostic models using a higher amount of data, whose results will serve to predict the health status in real-time at the edge. The so-built PHM system would allow industries to monitor and supervise a machinery network placed in different locations and can thus bring several benefits to both machinery producers and users. After a brief literature review of signal processing, feature extraction, diagnostics, and prognostics, including incremental and semi-supervised approaches for anomaly and novelty detection applied to data streams, a case study is presented. It was conducted on data collected from a test rig and shows the potential of the proposed framework in terms of the ability to detect changes in the operating conditions and abrupt faults and storage memory saving. The outcomes of our work, as well as its major novel aspect, is the design of a framework for a PHM system based on specific requirements that directly originate from the industrial field, together with indications on which techniques can be adopted to achieve such goals

Real-Time Machine Learning Based Open Switch Fault Detection and Isolation for Multilevel Multiphase Drives

Due to the rapid proliferation interest of the multiphase machines and their combination with multilevel inverters technology, the demand for high reliability and resilient in the multiphase multilevel drives is increased. High reliability can be achieved by deploying systematic preventive real-time monitoring, robust control, and efficient fault diagnosis strategies. Fault diagnosis, as an indispensable methodology to preserve the seamless post-fault operation, is carried out in consecutive steps; monitoring the observable signals to generate the residuals, evaluating the observations to make a binary decision if any abnormality has occurred, and identifying the characteristics of the abnormalities to locate and isolate the failed components. It is followed by applying an appropriate reconfiguration strategy to ensure that the system can tolerate the failure. The primary focus of presented dissertation was to address employing computational and machine learning techniques to construct a proficient fault diagnosis scheme in multilevel multiphase drives. First, the data-driven nonlinear model identification/prediction methods are used to form a hybrid fault detection framework, which combines module-level and system-level methods in power converters, to enhance the performance and obtain a rapid real-time detection. Applying suggested nonlinear model predictors along with different systems (conventional two-level inverter and three-level neutral point clamped inverter) result in reducing the detection time to 1% of stator current fundamental period without deploying component-level monitoring equipment. Further, two methods using semi-supervised learning and analytical data mining concepts are presented to isolate the failed component. The semi-supervised fuzzy algorithm is engaged in building the clustering model because the deficient labeled datasets (prior knowledge of the system) leads to degraded performance in supervised clustering. Also, an analytical data mining procedure is presented based on data interpretability that yields two criteria to isolate the failure. A key part of this work also dealt with the discrimination between the post-fault characteristics, which are supposed to carry the data reflecting the fault influence, and the output responses, which are compensated by controllers under closed-loop control strategy. The performance of all designed schemes is evaluated through experiments

A reusable knowledge acquisition shell: KASH

KASH (Knowledge Acquisition SHell) is proposed to assist a knowledge engineer by providing a set of utilities for constructing knowledge acquisition sessions based on interviewing techniques. The information elicited from domain experts during the sessions is guided by a question dependency graph (QDG). The QDG defined by the knowledge engineer, consists of a series of control questions about the domain that are used to organize the knowledge of an expert. The content information supplies by the expert, in response to the questions, is represented in the form of a concept map. These maps can be constructed in a top-down or bottom-up manner by the QDG and used by KASH to generate the rules for a large class of expert system domains. Additionally, the concept maps can support the representation of temporal knowledge. The high degree of reusability encountered in the QDG and concept maps can vastly reduce the development times and costs associated with producing intelligent decision aids, training programs, and process control functions

State Estimation of Timed Discrete Event Systems and Its Applications

Many industrial control systems can be described as discrete event systems (DES), whose state space is a discrete set where event occurrences cause transitions from one state to another. Timing introduces an additional dimension to DES modeling and control. This dissertation provides two models of timed DES endowed with a single clock, namely timed finite automata (TFA) and generalized timed finite automata (GTFA). In addition, a timing function is defined to associate each transition with a time interval specifying at which clock values it may occur. While the clock of a TFA is reset to zero after each event occurs and the time semantics constrain the dwell time at each discrete state, there is an additional clock resetting function associated with a GTFA to denote whether the clock is reset to a value in a given closed time interval. We assume that the logical and time structure of a partially observable TFA/GTFA is known. The main results are summarized as follows. 1. The notion of a zone automaton is introduced as a finite automaton providing a purely discrete event description of the behaviour of a TFA/GTFA of interest. Each state of a zone automaton contains a discrete state of the timed DES and a zone that is a time interval denoting a range of possible clock values. We investigate the dynamics of a zone automaton and show that one can reduce the problem of investigating the reachability of a given timed DES to the reachability analysis of a zone automaton. 2. We present a formal approach that allows one to construct offline an observer for TFA/GTFA, i.e., a finite structure that describes the state estimation for all possible evolutions. During the online phase to estimate the current discrete state according to each measurement of an observable event, one can determine which is the state of the observer reached by the current observation and check to which interval (among a finite number of time intervals) the time elapsed since the last observed event occurrence belongs. We prove that the discrete states consistent with a timed observation and the range of clock values associated with each estimated discrete state can be inferred following a certain number of runs in the zone automaton. In particular, the state estimation of timed DES under multiple clocks can be investigated in the framework of GTFA. We model such a system as a GTFA with multiple clocks, which generalizes the timing function and the clock resetting function to multiple clocks. 3. As an application of the state estimation approach for TFA, we assume that a given TFA may be affected by a set of faults described using timed transitions and aim at diagnosing a fault behaviour based on a timed observation. The problem of fault diagnosis is solved by constructing a zone automaton of the TFA with faults and a fault recognizer as the parallel composition of the zone automaton and a fault monitor that recognizes the occurrence of faults. We conclude that the occurrence of faults can be analyzed by exploring runs in the fault recognizer that are consistent with a given timed observation. 4. We also study the problem of attack detection in the context of DESs, assuming that a system may be subject to multiple types of attacks, each described by its own attack dictionary. Furthermore, we distinguish between constant attacks, which corrupt observations using only one of the attack dictionaries, and switching attacks, which may use different attack dictionaries at different steps. The problem we address is detecting whether a system has been attacked and, if so, which attack dictionaries have been used. To solve it in the framework of untimed DES, we construct a new structure that describes the observations generated by a system under attack. We show that the attack detection problem can be transformed into a classical state estimation/diagnosis problem for these new structures

Advanced and novel modeling techniques for simulation, optimization and monitoring chemical engineering tasks with refinery and petrochemical unit applications

Engineers predict, optimize, and monitor processes to improve safety and profitability. Models automate these tasks and determine precise solutions. This research studies and applies advanced and novel modeling techniques to automate and aid engineering decision-making. Advancements in computational ability have improved modeling software’s ability to mimic industrial problems. Simulations are increasingly used to explore new operating regimes and design new processes. In this work, we present a methodology for creating structured mathematical models, useful tips to simplify models, and a novel repair method to improve convergence by populating quality initial conditions for the simulation’s solver. A crude oil refinery application is presented including simulation, simplification tips, and the repair strategy implementation. A crude oil scheduling problem is also presented which can be integrated with production unit models. Recently, stochastic global optimization (SGO) has shown to have success of finding global optima to complex nonlinear processes. When performing SGO on simulations, model convergence can become an issue. The computational load can be decreased by 1) simplifying the model and 2) finding a synergy between the model solver repair strategy and optimization routine by using the initial conditions formulated as points to perturb the neighborhood being searched. Here, a simplifying technique to merging the crude oil scheduling problem and the vertically integrated online refinery production optimization is demonstrated. To optimize the refinery production a stochastic global optimization technique is employed. Process monitoring has been vastly enhanced through a data-driven modeling technique Principle Component Analysis. As opposed to first-principle models, which make assumptions about the structure of the model describing the process, data-driven techniques make no assumptions about the underlying relationships. Data-driven techniques search for a projection that displays data into a space easier to analyze. Feature extraction techniques, commonly dimensionality reduction techniques, have been explored fervidly to better capture nonlinear relationships. These techniques can extend data-driven modeling’s process-monitoring use to nonlinear processes. Here, we employ a novel nonlinear process-monitoring scheme, which utilizes Self-Organizing Maps. The novel techniques and implementation methodology are applied and implemented to a publically studied Tennessee Eastman Process and an industrial polymerization unit