An Intelligent Automatic Fault Detection Technique Incorporating Image Processing and Fuzzy Logic

Fault detection is considered an important and challenging task to be incorporated in many industrial applications. It has gained interest in recent years, and many techniques have been proposed for developing an effective fault detection approach due to its significant importance in everyday life. This study presents an automated intelligent fault detection technique incorporating image processing and fuzzy logic. Image processing is the first step where features such as entropy estimation, color-based segmentation and depth estimation from gradients are obtained. The extracted features (number of {blobs, minima, maxima}, and estimated entropy) act as input to the fuzzy logic. The subsequent step incorporates fuzzy logic; the four inputs are fed to fuzzy which extract the fault and acts as knowledge rule-based tool and final step, i.e. the output generation, classifies it accordingly into four categories of faults (rust, bumps, hole, wrinkles/roller marks). The proposed method is compared with Linear Vector Quantization, and Multivariate Discriminant Function approaches. The method is tested on a database of 150 images. The proposed method demonstrated its significance and effectiveness with performance accuracy of 99%, 98%, 96.8% and 97.6% for rust, bumps, holes and wrinkles/roller marks respectively

Sensor based real-time process monitoring for ultra-precision manufacturing processes with non-linearity and non-stationarity

This research investigates methodologies for real-time process monitoring in ultra-precision manufacturing processes, specifically, chemical mechanical planarization (CMP) and ultra-precision machining (UPM), are investigated in this dissertation.The three main components of this research are as follows: (1) developing a predictive modeling approaches for early detection of process anomalies/change points, (2) devising approaches that can capture the non-Gaussian and non-stationary characteristics of CMP and UPM processes, and (3) integrating multiple sensor data to make more reliable process related decisions in real-time.In the first part, we establish a quantitative relationship between CMP process performance, such as material removal rate (MRR) and data acquired from wireless vibration sensors. Subsequently, a non-linear sequential Bayesian analysis is integrated with decision theoretic concepts for detection of CMP process end-point for blanket copper wafers. Using this approach, CMP polishing end-point was detected within a 5% error rate.Next, a non-parametric Bayesian analytical approach is utilized to capture the inherently complex, non-Gaussian, and non-stationary sensor signal patterns observed in CMP process. An evolutionary clustering analysis, called Recurrent Nested Dirichlet Process (RNDP) approach is developed for monitoring CMP process changes using MEMS vibration signals. Using this novel signal analysis approach, process drifts are detected within 20 milliseconds and is assessed to be 3-7 times faster than traditional SPC charts. This is very beneficial to the industry from an application standpoint, because, wafer yield losses will be mitigated to a great extent, if the onset of CMP process drifts can be detected timely and accurately.Lastly, a non-parametric Bayesian modeling approach, termed Dirichlet Process (DP) is combined with a multi-level hierarchical information fusion technique for monitoring of surface finish in UPM process. Using this approach, signal patterns from six different sensors (three axis vibration and force) are integrated based on information fusion theory. It was observed that using experimental UPM sensor data that process decisions based on the multiple sensor information fusion approach were 15%-30% more accurate than the decisions from individual sensors. This will enable more accurate and reliable estimation of process conditions in ultra-precision manufacturing applications

Methods and Systems for Fault Diagnosis in Nuclear Power Plants

This research mainly deals with fault diagnosis in nuclear power plants (NPP), based on a framework that integrates contributions from fault scope identification, optimal sensor placement, sensor validation, equipment condition monitoring, and diagnostic reasoning based on pattern analysis. The research has a particular focus on applications where data collected from the existing SCADA (supervisory, control, and data acquisition) system is not sufficient for the fault diagnosis system. Specifically, the following methods and systems are developed. A sensor placement model is developed to guide optimal placement of sensors in NPPs. The model includes 1) a method to extract a quantitative fault-sensor incidence matrix for a system; 2) a fault diagnosability criterion based on the degree of singularities of the incidence matrix; and 3) procedures to place additional sensors to meet the diagnosability criterion. Usefulness of the proposed method is demonstrated on a nuclear power plant process control test facility (NPCTF). Experimental results show that three pairs of undiagnosable faults can be effectively distinguished with three additional sensors selected by the proposed model. A wireless sensor network (WSN) is designed and a prototype is implemented on the NPCTF. WSN is an effective tool to collect data for fault diagnosis, especially for systems where additional measurements are needed. The WSN has distributed data processing and information fusion for fault diagnosis. Experimental results on the NPCTF show that the WSN system can be used to diagnose all six fault scenarios considered for the system. A fault diagnosis method based on semi-supervised pattern classification is developed which requires significantly fewer training data than is typically required in existing fault diagnosis models. It is a promising tool for applications in NPPs, where it is usually difficult to obtain training data under fault conditions for a conventional fault diagnosis model. The proposed method has successfully diagnosed nine types of faults physically simulated on the NPCTF. For equipment condition monitoring, a modified S-transform (MST) algorithm is developed by using shaping functions, particularly sigmoid functions, to modify the window width of the existing standard S-transform. The MST can achieve superior time-frequency resolution for applications that involves non-stationary multi-modal signals, where classical methods may fail. Effectiveness of the proposed algorithm is demonstrated using a vibration test system as well as applications to detect a collapsed pipe support in the NPCTF. The experimental results show that by observing changes in time-frequency characteristics of vibration signals, one can effectively detect faults occurred in components of an industrial system. To ensure that a fault diagnosis system does not suffer from erroneous data, a fault detection and isolation (FDI) method based on kernel principal component analysis (KPCA) is extended for sensor validations, where sensor faults are detected and isolated from the reconstruction errors of a KPCA model. The method is validated using measurement data from a physical NPP. The NPCTF is designed and constructed in this research for experimental validations of fault diagnosis methods and systems. Faults can be physically simulated on the NPCTF. In addition, the NPCTF is designed to support systems based on different instrumentation and control technologies such as WSN and distributed control systems. The NPCTF has been successfully utilized to validate the algorithms and WSN system developed in this research. In a real world application, it is seldom the case that one single fault diagnostic scheme can meet all the requirements of a fault diagnostic system in a nuclear power. In fact, the values and performance of the diagnosis system can potentially be enhanced if some of the methods developed in this thesis can be integrated into a suite of diagnostic tools. In such an integrated system, WSN nodes can be used to collect additional data deemed necessary by sensor placement models. These data can be integrated with those from existing SCADA systems for more comprehensive fault diagnosis. An online performance monitoring system monitors the conditions of the equipment and provides key information for the tasks of condition-based maintenance. When a fault is detected, the measured data are subsequently acquired and analyzed by pattern classification models to identify the nature of the fault. By analyzing the symptoms of the fault, root causes of the fault can eventually be identified

Advanced Occupancy Measurement Using Sensor Fusion

With roughly about half of the energy used in buildings attributed to Heating, Ventilation, and Air conditioning (HVAC) systems, there is clearly great potential for energy saving through improved building operations. Accurate knowledge of localised and real-time occupancy numbers can have compelling control applications for HVAC systems. However, existing technologies applied for building occupancy measurements are limited, such that a precise and reliable occupant count is difficult to obtain. For example, passive infrared (PIR) sensors commonly used for occupancy sensing in lighting control applications cannot differentiate between occupants grouped together, video sensing is often limited by privacy concerns, atmospheric gas sensors (such as CO2 sensors) may be affected by the presence of electromagnetic (EMI) interference, and may not show clear links between occupancy and sensor values. Past studies have indicated the need for a heterogeneous multi-sensory fusion approach for occupancy detection to address the short-comings of existing occupancy detection systems. The aim of this research is to develop an advanced instrumentation strategy to monitor occupancy levels in non-domestic buildings, whilst facilitating the lowering of energy use and also maintaining an acceptable indoor climate. Accordingly, a novel multi-sensor based approach for occupancy detection in open-plan office spaces is proposed. The approach combined information from various low-cost and non-intrusive indoor environmental sensors, with the aim to merge advantages of various sensors, whilst minimising their weaknesses. The proposed approach offered the potential for explicit information indicating occupancy levels to be captured. The proposed occupancy monitoring strategy has two main components; hardware system implementation and data processing. The hardware system implementation included a custom made sound sensor and refinement of CO2 sensors for EMI mitigation. Two test beds were designed and implemented for supporting the research studies, including proof-of-concept, and experimental studies. Data processing was carried out in several stages with the ultimate goal being to detect occupancy levels. Firstly, interested features were extracted from all sensory data collected, and then a symmetrical uncertainty analysis was applied to determine the predictive strength of individual sensor features. Thirdly, a candidate features subset was determined using a genetic based search. Finally, a back-propagation neural network model was adopted to fuse candidate multi-sensory features for estimation of occupancy levels. Several test cases were implemented to demonstrate and evaluate the effectiveness and feasibility of the proposed occupancy detection approach. Results have shown the potential of the proposed heterogeneous multi-sensor fusion based approach as an advanced strategy for the development of reliable occupancy detection systems in open-plan office buildings, which can be capable of facilitating improved control of building services. In summary, the proposed approach has the potential to: (1) Detect occupancy levels with an accuracy reaching 84.59% during occupied instances (2) capable of maintaining average occupancy detection accuracy of 61.01%, in the event of sensor failure or drop-off (such as CO2 sensors drop-off), (3) capable of utilising just sound and motion sensors for occupancy levels monitoring in a naturally ventilated space, (4) capable of facilitating potential daily energy savings reaching 53%, if implemented for occupancy-driven ventilation control