Fault diagnosis by multisensor data: A data-driven approach based on spectral clustering and pairwise constraints

This paper deals with clustering based on feature selection of multisensor data in high-dimensional space. Spectral clustering algorithms are efficient tools in signal processing for grouping datasets sampled by multisensor systems for fault diagnosis. The effectiveness of spectral clustering stems from constructing an embedding space based on an affinity matrix. This matrix shows the pairwise similarity of the data points. Clustering is then obtained by determining the spectral decomposition of the Laplacian graph. In the manufacturing field, clustering is an essential strategy for fault diagnosis. In this study, an enhanced spectral clustering approach is presented, which is augmented with pairwise constraints, and that results in efficient identification of fault scenarios. The effectiveness of the proposed approach is described using a real case study about a diesel injection control system for fault detection

In-Cylinder Pressure Estimation from Rotational Speed Measurements via Extended Kalman Filter

Real-time estimation of the in-cylinder pressure of combustion engines is crucial to detect failures and improve the performance of the engine control system. A new estimation scheme is proposed based on the Extended Kalman Filter, which exploits measurements of the engine rotational speed provided by a standard phonic wheel sensor. The main novelty lies in a parameterization of the combustion pressure, which is generated by averaging experimental data collected in different operating points. The proposed approach is validated on real data from a turbocharged compression ignition engine, including both nominal and off-nominal working conditions. The experimental results show that the proposed technique accurately reconstructs the pressure profile, featuring a fit performance index exceeding 90% most of the time. Moreover, it can track changes in the engine operating conditions as well as detect the presence of cylinder-to-cylinder variations

Vibration-Based structural health monitoring using piezoelectric transducers and parametric t-SNE

In this paper, we evaluate the performance of the so-called parametric t-distributed stochastic neighbor embedding (P-t-SNE), comparing it to the performance of the t-SNE, the non-parametric version. The methodology used in this study is introduced for the detection and classification of structural changes in the field of structural health monitoring. This method is based on the combination of principal component analysis (PCA) and P-t-SNE, and it is applied to an experimental case study of an aluminum plate with four piezoelectric transducers. The basic steps of the detection and classification process are: (i) the raw data are scaled using mean-centered group scaling and then PCA is applied to reduce its dimensionality; (ii) P-t-SNE is applied to represent the scaled and reduced data as 2-dimensional points, defining a cluster for each structural state; and (iii) the current structure to be diagnosed is associated with a cluster employing two strategies: (a) majority voting; and (b) the sum of the inverse distances. The results in the frequency domain manifest the strong performance of P-t-SNE, which is comparable to the performance of t-SNE but outperforms t-SNE in terms of computational cost and runtime. When the method is based on P-t-SNE, the overall accuracy fluctuates between 99.5% and 99.75%.Peer ReviewedPostprint (published version

Eco-friendly Naturalistic Vehicular Sensing and Driving Behaviour Profiling

PhD ThesisInternet of Things (IoT) technologies are spurring of serious games that support training directly in the field. This PhD implements field user performance evaluators usable in reality-enhanced serious games (RESGs) for promoting fuel-efficient driving. This work proposes two modules – that have been implemented by processing information related to fuel-efficient driving – to be employed as real-time virtual sensors in RESGS. The first module estimates and assesses instantly fuel consumption, where I compared the performance of three configured machine learning algorithms, support vector regression, random forest and artificial neural networks. The experiments show that the algorithms have similar performance and random forest slightly outperforms the others. The second module provides instant recommendations using fuzzy logic when inefficient driving patterns are detected. For the game design, I resorted to the on-board diagnostics II standard interface to diagnostic circulating information on vehicular buses for a wide diffusion of a game, avoiding sticking to manufacturer proprietary solutions. The approach has been implemented and tested with data from the enviroCar server site. The data is not calibrated for a specific car model and is recorded in different driving environments, which made the work challenging and robust for real-world conditions. The proposed approach to virtual sensor design is general and thus applicable to various application domains other than fuel-efficient driving. An important word of caution concerns users’ privacy, as the modules rely on sensitive data, and provide information that by no means should be misused

Acoustic emission monitoring of propulsion systems : a laboratory study on a small gas turbine

The motivation of the work is to investigate a new, non-intrusive condition monitoring system for gas turbines with capabilities for earlier identification of any changes and the possibility of locating the source of the faults. This thesis documents experimental research conducted on a laboratory-scale gas turbine to assess the monitoring capabilities of Acoustic Emission (AE). In particular it focuses on understanding the AE behaviour of gas turbines under various normal and faulty running conditions. A series of tests was performed with the turbine running normally, either idling or with load. Two abnormal running configurations were also instrumented in which the impeller was either prevented from rotation or removed entirely. With the help of demodulated resonance analysis and an ANN it was possible to identify two types of AE; a background broadband source which is associated with gas flow and flow resistance, and a set of spectral frequency peaks which are associated with reverberation in the exhaust and coupling between the alternator and the turbine. A second series of experiments was carried out with an impeller which had been damaged by removal of the tips of some of the blades (two damaged blades and four damaged blades). The results show the potential capability of AE to identify gas turbine blade faults. The AE records showed two obvious indicators of blade faults, the first being that the energy in the AE signals becomes much higher and is distinctly periodic at higher speeds, and the second being the appearance of particular pulse patterns which can be characterized in the demodulated frequency domain

A novel framework for enhancing marine dual fuel engines environmental and safety performance via digital twins

The Internet of Things (IoT) advent and digitalisation has enabled the effective application of the digital twins (DT) in various industries, including shipping, with expected benefits on the systems safety, efficiency and environmental footprint. The present research study establishes a novel framework that aims to optimise the marine DF engines performance-emissions trade-offs and enhance their safety, whilst delineating the involved interactions and their effect on the performance and safety. The framework employs a DT, which integrates a thermodynamic engine model along with control function and safety systems modelling. The DT was developed in GT-ISE© environment. Both the gas and diesel operating modes are investigated under steady state and transient conditions. The engine layout is modified to include Exhaust Gas Recirculation (EGR) and Air Bypass (ABP) systems for ensuring compliance with ‘Tier III’ emissions requirements. The optimal DF engine settings as well as the EGR/ABP systems settings for optimal engine efficiency and reduced emissions are identified in both gas and diesel modes, by employing a combination of optimisation techniques including multi-objective genetic algorithms (MOGA) and Design of Experiments (DoE) parametric runs. This study addresses safety by developing an intelligent engine monitoring and advanced faults/failure diagnostics systems, which evaluates the sensors measurements uncertainty. A Failure Mode Effects and Analysis (FMEA) is employed to identify the engine safety critical components, which are used to specify operating scenarios for detailed investigation with the developed DT. The integrated DT is further expanded, by establishing a Faulty Operation Simulator (FOS) to simulate the FMEA scenarios and assess the engine safety implications. Furthermore, an Engine Diagnostics System (EDS) is developed, which offers intelligent engine monitoring, advanced diagnostics and profound corrective actions. This is accomplished by developing and employing a Data-Driven (DD) model based on Neural Networks (NN), along with logic controls, all incorporated in the EDS. Lastly, the manufacturer’s and proposed engine control systems are combined to form an innovative Unified Digital System (UDS), which is also included in the DT. The analysis of marine (DF) engines with the use of an innovative DT, as presented herein, is paving the way towards smart shipping.The Internet of Things (IoT) advent and digitalisation has enabled the effective application of the digital twins (DT) in various industries, including shipping, with expected benefits on the systems safety, efficiency and environmental footprint. The present research study establishes a novel framework that aims to optimise the marine DF engines performance-emissions trade-offs and enhance their safety, whilst delineating the involved interactions and their effect on the performance and safety. The framework employs a DT, which integrates a thermodynamic engine model along with control function and safety systems modelling. The DT was developed in GT-ISE© environment. Both the gas and diesel operating modes are investigated under steady state and transient conditions. The engine layout is modified to include Exhaust Gas Recirculation (EGR) and Air Bypass (ABP) systems for ensuring compliance with ‘Tier III’ emissions requirements. The optimal DF engine settings as well as the EGR/ABP systems settings for optimal engine efficiency and reduced emissions are identified in both gas and diesel modes, by employing a combination of optimisation techniques including multi-objective genetic algorithms (MOGA) and Design of Experiments (DoE) parametric runs. This study addresses safety by developing an intelligent engine monitoring and advanced faults/failure diagnostics systems, which evaluates the sensors measurements uncertainty. A Failure Mode Effects and Analysis (FMEA) is employed to identify the engine safety critical components, which are used to specify operating scenarios for detailed investigation with the developed DT. The integrated DT is further expanded, by establishing a Faulty Operation Simulator (FOS) to simulate the FMEA scenarios and assess the engine safety implications. Furthermore, an Engine Diagnostics System (EDS) is developed, which offers intelligent engine monitoring, advanced diagnostics and profound corrective actions. This is accomplished by developing and employing a Data-Driven (DD) model based on Neural Networks (NN), along with logic controls, all incorporated in the EDS. Lastly, the manufacturer’s and proposed engine control systems are combined to form an innovative Unified Digital System (UDS), which is also included in the DT. The analysis of marine (DF) engines with the use of an innovative DT, as presented herein, is paving the way towards smart shipping

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

Real-time multi-domain optimization controller for multi-motor electric vehicles using automotive-suitable methods and heterogeneous embedded platforms

Los capítulos 2,3 y 7 están sujetos a confidencialidad por el autor. 145 p.In this Thesis, an elaborate control solution combining Machine Learning and Soft Computing techniques has been developed, targeting a chal lenging vehicle dynamics application aiming to optimize the torque distribution across the wheels with four independent electric motors.The technological context that has motivated this research brings together potential -and challenges- from multiple dom ains: new automotive powertrain topologies with increased degrees of freedom and controllability, which can be approached with innovative Machine Learning algorithm concepts, being implementable by exploiting the computational capacity of modern heterogeneous embedded platforms and automated toolchains. The complex relations among these three domains that enable the potential for great enhancements, do contrast with the fourth domain in this context: challenging constraints brought by industrial aspects and safe ty regulations. The innovative control architecture that has been conce ived combines Neural Networks as Virtual Sensor for unmeasurable forces , with a multi-objective optimization function driven by Fuzzy Logic , which defines priorities basing on the real -time driving situation. The fundamental principle is to enhance vehicle dynamics by implementing a Torque Vectoring controller that prevents wheel slip using the inputs provided by the Neural Network. Complementary optimization objectives are effici ency, thermal stress and smoothness. Safety -critical concerns are addressed through architectural and functional measures.Two main phases can be identified across the activities and milestones achieved in this work. In a first phase, a baseline Torque Vectoring controller was implemented on an embedded platform and -benefiting from a seamless transition using Hardware-in -the -Loop - it was integrated into a real Motor -in -Wheel vehicle for race track tests. Having validated the concept, framework, methodology and models, a second simulation-based phase proceeds to develop the more sophisticated controller, targeting a more capable vehicle, leading to the final solution of this work. Besides, this concept was further evolved to support a joint research work which lead to outstanding FPGA and GPU based embedded implementations of Neural Networks. Ultimately, the different building blocks that compose this work have shown results that have met or exceeded the expectations, both on technical and conceptual level. The highly non-linear multi-variable (and multi-objective) control problem was tackled. Neural Network estimations are accurate, performance metrics in general -and vehicle dynamics and efficiency in particular- are clearly improved, Fuzzy Logic and optimization behave as expected, and efficient embedded implementation is shown to be viable. Consequently, the proposed control concept -and the surrounding solutions and enablers- have proven their qualities in what respects to functionality, performance, implementability and industry suitability.The most relevant contributions to be highlighted are firstly each of the algorithms and functions that are implemented in the controller solutions and , ultimately, the whole control concept itself with the architectural approaches it involves. Besides multiple enablers which are exploitable for future work have been provided, as well as an illustrative insight into the intricacies of a vivid technological context, showcasing how they can be harmonized. Furthermore, multiple international activities in both academic and professional contexts -which have provided enrichment as well as acknowledgement, for this work-, have led to several publications, two high-impact journal papers and collateral work products of diverse nature

Real-time multi-domain optimization controller for multi-motor electric vehicles using automotive-suitable methods and heterogeneous embedded platforms

Los capítulos 2,3 y 7 están sujetos a confidencialidad por el autor. 145 p.In this Thesis, an elaborate control solution combining Machine Learning and Soft Computing techniques has been developed, targeting a chal lenging vehicle dynamics application aiming to optimize the torque distribution across the wheels with four independent electric motors.The technological context that has motivated this research brings together potential -and challenges- from multiple dom ains: new automotive powertrain topologies with increased degrees of freedom and controllability, which can be approached with innovative Machine Learning algorithm concepts, being implementable by exploiting the computational capacity of modern heterogeneous embedded platforms and automated toolchains. The complex relations among these three domains that enable the potential for great enhancements, do contrast with the fourth domain in this context: challenging constraints brought by industrial aspects and safe ty regulations. The innovative control architecture that has been conce ived combines Neural Networks as Virtual Sensor for unmeasurable forces , with a multi-objective optimization function driven by Fuzzy Logic , which defines priorities basing on the real -time driving situation. The fundamental principle is to enhance vehicle dynamics by implementing a Torque Vectoring controller that prevents wheel slip using the inputs provided by the Neural Network. Complementary optimization objectives are effici ency, thermal stress and smoothness. Safety -critical concerns are addressed through architectural and functional measures.Two main phases can be identified across the activities and milestones achieved in this work. In a first phase, a baseline Torque Vectoring controller was implemented on an embedded platform and -benefiting from a seamless transition using Hardware-in -the -Loop - it was integrated into a real Motor -in -Wheel vehicle for race track tests. Having validated the concept, framework, methodology and models, a second simulation-based phase proceeds to develop the more sophisticated controller, targeting a more capable vehicle, leading to the final solution of this work. Besides, this concept was further evolved to support a joint research work which lead to outstanding FPGA and GPU based embedded implementations of Neural Networks. Ultimately, the different building blocks that compose this work have shown results that have met or exceeded the expectations, both on technical and conceptual level. The highly non-linear multi-variable (and multi-objective) control problem was tackled. Neural Network estimations are accurate, performance metrics in general -and vehicle dynamics and efficiency in particular- are clearly improved, Fuzzy Logic and optimization behave as expected, and efficient embedded implementation is shown to be viable. Consequently, the proposed control concept -and the surrounding solutions and enablers- have proven their qualities in what respects to functionality, performance, implementability and industry suitability.The most relevant contributions to be highlighted are firstly each of the algorithms and functions that are implemented in the controller solutions and , ultimately, the whole control concept itself with the architectural approaches it involves. Besides multiple enablers which are exploitable for future work have been provided, as well as an illustrative insight into the intricacies of a vivid technological context, showcasing how they can be harmonized. Furthermore, multiple international activities in both academic and professional contexts -which have provided enrichment as well as acknowledgement, for this work-, have led to several publications, two high-impact journal papers and collateral work products of diverse nature

Proceedings of the Scientific-Practical Conference "Research and Development - 2016"

talent management; sensor arrays; automatic speech recognition; dry separation technology; oil production; oil waste; laser technolog