An intelligent engine condition monitoring system

The main focus of the work reported here is in the design of an intelligent condition monitoring system for diesel engines. Mechanical systems in general and diesel engines in particular can develop faults if operated for any length of time. Condition monitoring is a method by which the performance of a diesel engine can be maintained at a high level, ensuring both continuous availability and design-level efficiency. A key element in a condition monitoring program is to acquire sensor information from the engine, and use this information to assess the condition of the engine, with an emphasis on monitoring causes of engine failure or reduced efficiency. A Ford 70PS 4-stroke diesel engine has been instrumented with a range of sensors and interfaced to a PC in order to facilitate computer controlled data acquisition and data storage. Data was analyzed to evaluate the optimum use of sensors to identify faults and to develop an intelligent algorithm for the engine condition monitoring and fault detection, and in particular faults affecting the combustion process in the engine. In order to investigate the fault-symptom relationships, two synthetic faults were introduced to the engine. Fuel and inlet air shortage were selected as the faults for their direct relationship to the combustion process quality. As a subtask the manually operated hydraulic brake was adapted to allow automatic control to improve its performance. Two modes of controlling were designed for the developed automatic control of the hydraulic brake system. A robust mathematical diesel engine model has been developed which can be used to predict the engine parameters related to the combustion process in the diesel engine, was constructed from the basic relationships of the diesel engine using the minimum number of empirical equations. The system equations of a single cylinder engine were initially developed, from which the multi-cylinder diesel engine model was validated against experimental test data. The model was then tuned to improve the predicted engine parameters for better matching with the available engine type. The final four-cylinder diesel engine model was verified and the results show an accurate match with the experimental results. Neural networks and fuzzification were used to develop and validate the intelligent condition monitoring and fault diagnosis algorithm, in order to satisfy the requirements of on-line operation, i. e. reliability, easily trained, minimum hardware and software requirements. The development process used a number of different neural network architecture and training techniques. To increase the number of the parameters used for the engine condition evaluation, the Multi-Net technique was used to satisfy accurate and fast decision making. Two neural networks are designed to operate in parallel to accommodate the different sampling rate of the key parameters without interference and with reduced data processing time. The two neural networks were trained and validated using part of the measured data set that represents the engine operating range. Another set of data, not utilized within the training stage, has been applied for validation. The results of validation process indicate the successful prediction of the faults using the key measured parameters, as well as a fast data processing algorithm. One of the main outcomes of this study is the development of a new technique to measure cylinder pressure and fuel pressure through the measurement of the strain in the injector body. The main advantage of this technique is that, it does not require any intrusive modification to the engine which might affect the engine actual performance. The developed sensor was tested and used to measure the cylinder and fuel pressure to verify the fuel fault effect on the combustion process quality. Due to high sampling rate required, the developed condition monitoring and fault diagnosis algorithm does not utilize this signal to reduce the required computational resources for practical applications.EThOS - Electronic Theses Online ServiceEgyptian GovernmentGBUnited Kingdo

Meta-heuristic algorithms in car engine design: a literature survey

Meta-heuristic algorithms are often inspired by natural phenomena, including the evolution of species in Darwinian natural selection theory, ant behaviors in biology, flock behaviors of some birds, and annealing in metallurgy. Due to their great potential in solving difficult optimization problems, meta-heuristic algorithms have found their way into automobile engine design. There are different optimization problems arising in different areas of car engine management including calibration, control system, fault diagnosis, and modeling. In this paper we review the state-of-the-art applications of different meta-heuristic algorithms in engine management systems. The review covers a wide range of research, including the application of meta-heuristic algorithms in engine calibration, optimizing engine control systems, engine fault diagnosis, and optimizing different parts of engines and modeling. The meta-heuristic algorithms reviewed in this paper include evolutionary algorithms, evolution strategy, evolutionary programming, genetic programming, differential evolution, estimation of distribution algorithm, ant colony optimization, particle swarm optimization, memetic algorithms, and artificial immune system

Combining diverse neural nets

An appropriate use of neural computing techniques is to apply them to problems such as condition monitoring, fault diagnosis, control and sensing, where conventional solutions can be hard to obtain. However, when neural computing techniques are used, it is important that they are employed so as to maximise their performance, and improve their reliability. Their performance is typically assessed in terms of their ability to generalise to a previously unseen test set, although unless the training set is very carefully chosen, 100% accuracy is rarely achieved. Improved performance can result when sets of neural nets are combined in ensembles and ensembles can be viewed as an example of the reliability through redundancy approach that is recommended for conventional software and hardware in safety-critical or safety-related applications. Although there has been recent interest in the use of neural net ensembles, such techniques have yet to be applied to the tasks of condition monitoring and fault diagnosis. In this paper, we focus on the benefits of techniques which promote diversity amongst the members of an ensemble, such that there is a minimum number of coincident failures. The concept of ensemble diversity is considered in some detail, and a hierarchy of four levels of diversity is presented. This hierarchy is then used in the description of the application of ensemble-based techniques to the case study of fault diagnosis of a diesel engine

A decision support system for the development of voyage and maintenance plans for ships

The waterborne sector faces nowadays significant challenges due to several environmental, financial and other concerns. Such challenges may be addressed, among others, by optimising voyage plans, and diagnosing as early as possible engine failures that may lead to performance degradation. These two issues are addressed by the Decision Support System (DSS) presented herein, which focuses on the operation of merchant ships. For the development of voyage plans, a multicriteria decision problem is developed and handled with the PROMETHE method, while a multivariable control chart is used for the fault diagnosis problem. A MATLAB-based software implementation of the DSS has been developed adopting a modular architecture, while, in order to provide a generic software solution, the required input data are retrieved from dedicated web-services, following specific communication and data exchange protocols

Artificial neural networks and physical modeling for determination of baseline consumption of CHP plants

An effective modeling technique is proposed for determining baseline energy consumption in the industry. A CHP plant is considered in the study that was subjected to a retrofit, which consisted of the implementation of some energy-saving measures. This study aims to recreate the post-retrofit energy consumption and production of the system in case it would be operating in its past configuration (before retrofit) i.e., the current consumption and production in the event that no energy-saving measures had been implemented. Two different modeling methodologies are applied to the CHP plant: thermodynamic modeling and artificial neural networks (ANN). Satisfactory results are obtained with both modeling techniques. Acceptable accuracy levels of prediction are detected, confirming good capability of the models for predicting plant behavior and their suitability for baseline energy consumption determining purposes. High level of robustness is observed for ANN against uncertainty affecting measured values of variables used as input in the models. The study demonstrates ANN great potential for assessing baseline consumption in energyintensive industry. Application of ANN technique would also help to overcome the limited availability of on-shelf thermodynamic software for modeling all specific typologies of existing industrial processes

A review of physics-based models in prognostics: application to gears and bearings of rotating machinery

Health condition monitoring for rotating machinery has been developed for many years due to its potential to reduce the cost of the maintenance operations and increase availability. Covering aspects include sensors, signal processing, health assessment and decision-making. This article focuses on prognostics based on physics-based models. While the majority of the research in health condition monitoring focuses on data-driven techniques, physics-based techniques are particularly important if accuracy is a critical factor and testing is restricted. Moreover, the benefits of both approaches can be combined when data-driven and physics-based techniques are integrated. This article reviews the concept of physics-based models for prognostics. An overview of common failure modes of rotating machinery is provided along with the most relevant degradation mechanisms. The models available to represent these degradation mechanisms and their application for prognostics are discussed. Models that have not been applied to health condition monitoring, for example, wear due to metal–metal contact in hydrodynamic bearings, are also included due to its potential for health condition monitoring. The main contribution of this article is the identification of potential physics-based models for prognostics in rotating machinery

AUTOMATED DIESEL ENGINE CONDITION & PERFORMANCE MONITORING & THE APPLICATION OF NEURAL NETWORKS TO FAULT DIAGNOSIS

The overall aim of this research was to design, configure and validate a system which was capable of on-line performance monitoring and fault diagnosis of a diesel engine. This thesis details the development and evaluation of a comprehensive engine test facility and automated engine performance monitoring package. Results of a diesel engine fault study were used to ascertain commonly occurring faults and their realistic severities are discussed. The research shows how computer simulation and rig testing can be applied to validate the effects of faults on engine performance and quantify fault severities. A substantial amount of engine test work has been conducted to investigate the effects of various faults on high speed diesel engine performance. A detailed analysis of the engine test data has led to the development of explicit fault-symptom relationships and the identification of key sensors that may be fitted to a diesel engine for diagnostic purposes. The application of a neural network based approach to diesel engine fault diagnosis has been investigated. This work has included an assessment of neural network performance at engine torques and speeds where it was not trained, noisy engine data, faulty sensor data, varying fault severities and novel faults which were similar to those which the network had been trained on. The work has shown that diagnosis using raw neural network outputs under operational conditions would be inadequate. To overcome these inadequacies a new technique using an on-line diagnostic database incorporating 'weight adjusting' and 'confidence factor' algorithms has been developed and validated. The results show a neural network combined with an on-line diagnostic database can be successfully used for practical diesel engine fault diagnosis to offer a realistic alternative to current fault diagnosis techniques.The Ministry Of Defenc

Multi-source, multi-sensor approaches to diesel engine monitoring using acoustic emission

Abstract unavailable please refer to PD