Enhanced Industrial Machinery Condition Monitoring Methodology based on Novelty Detection and Multi-Modal Analysis

This paper presents a condition-based monitoring methodology based on novelty detection applied to industrial machinery. The proposed approach includes both, the classical classification of multiple a priori known scenarios, and the innovative detection capability of new operating modes not previously available. The development of condition-based monitoring methodologies considering the isolation capabilities of unexpected scenarios represents, nowadays, a trending topic able to answer the demanding requirements of the future industrial processes monitoring systems. First, the method is based on the temporal segmentation of the available physical magnitudes, and the estimation of a set of time-based statistical features. Then, a double feature reduction stage based on Principal Component Analysis and Linear Discriminant Analysis is applied in order to optimize the classification and novelty detection performances. The posterior combination of a Feed-forward Neural Network and One-Class Support Vector Machine allows the proper interpretation of known and unknown operating conditions. The effectiveness of this novel condition monitoring scheme has been verified by experimental results obtained from an automotive industry machine.Postprint (published version

Vibration-based adaptive novelty detection method for monitoring faults in a kinematic chain

Postprint (published version

Industrial data-driven monitoring based on incremental learning applied to the detection of novel faults

The detection of uncharacterized events during electromechanical systems operation represents one of the most critical data challenges dealing with condition-based monitoring under the Industry 4.0 framework. Thus, the detection of novelty conditions and the learning of new patterns are considered as mandatory competencies in modern industrial applications. In this regard, this article proposes a novel multifault detection and identification scheme, based on machine learning, information data-fusion, novelty-detection, and incremental learning. First, statistical time-domain features estimated from multiple physical magnitudes acquired from the electrical motor under inspection are fused under a feature-fusion level scheme. Second, a self-organizing map structure is proposed to construct a data-based model of the available conditions of operation. Third, the incremental learning of the condition-based monitoring scheme is performed adding self-organizing structures and optimizing their projections through a linear discriminant analysis. The performance of the proposed scheme is validated under a complete set of experimental scenarios from two different cases of study, and the results compared with a classical approach.Peer ReviewedPostprint (author's final draft

Evolving Clustering Algorithms And Their Application For Condition Monitoring, Diagnostics, & Prognostics

Applications of Condition-Based Maintenance (CBM) technology requires effective yet generic data driven methods capable of carrying out diagnostics and prognostics tasks without detailed domain knowledge and human intervention. Improved system availability, operational safety, and enhanced logistics and supply chain performance could be achieved, with the widespread deployment of CBM, at a lower cost level. This dissertation focuses on the development of a Mutual Information based Recursive Gustafson-Kessel-Like (MIRGKL) clustering algorithm which operates recursively to identify underlying model structure and parameters from stream type data. Inspired by the Evolving Gustafson-Kessel-like Clustering (eGKL) algorithm, we applied the notion of mutual information to the well-known Mahalanobis distance as the governing similarity measure throughout. This is also a special case of the Kullback-Leibler (KL) Divergence where between-cluster shape information (governed by the determinant and trace of the covariance matrix) is omitted and is only applicable in the case of normally distributed data. In the cluster assignment and consolidation process, we proposed the use of the Chi-square statistic with the provision of having different probability thresholds. Due to the symmetry and boundedness property brought in by the mutual information formulation, we have shown with real-world data that the algorithm’s performance becomes less sensitive to the same range of probability thresholds which makes system tuning a simpler task in practice. As a result, improvement demonstrated by the proposed algorithm has implications in improving generic data driven methods for diagnostics, prognostics, generic function approximations and knowledge extractions for stream type of data. The work in this dissertation demonstrates MIRGKL’s effectiveness in clustering and knowledge representation and shows promising results in diagnostics and prognostics applications

Hybrid incremental modeling based on least squares and fuzzy K-NN for monitoring tool wear in turning processes

There is now an emerging need for an efficient modeling strategy to develop a new generation of monitoring systems. One method of approaching the modeling of complex processes is to obtain a global model. It should be able to capture the basic or general behavior of the system, by means of a linear or quadratic regression, and then superimpose a local model on it that can capture the localized nonlinearities of the system. In this paper, a novel method based on a hybrid incremental modeling approach is designed and applied for tool wear detection in turning processes. It involves a two-step iterative process that combines a global model with a local model to take advantage of their underlying, complementary capacities. Thus, the first step constructs a global model using a least squares regression. A local model using the fuzzy k-nearest-neighbors smoothing algorithm is obtained in the second step. A comparative study then demonstrates that the hybrid incremental model provides better error-based performance indices for detecting tool wear than a transductive neurofuzzy model and an inductive neurofuzzy model

AI and OR in management of operations: history and trends

The last decade has seen a considerable growth in the use of Artificial Intelligence (AI) for operations management with the aim of finding solutions to problems that are increasing in complexity and scale. This paper begins by setting the context for the survey through a historical perspective of OR and AI. An extensive survey of applications of AI techniques for operations management, covering a total of over 1200 papers published from 1995 to 2004 is then presented. The survey utilizes Elsevier's ScienceDirect database as a source. Hence, the survey may not cover all the relevant journals but includes a sufficiently wide range of publications to make it representative of the research in the field. The papers are categorized into four areas of operations management: (a) design, (b) scheduling, (c) process planning and control and (d) quality, maintenance and fault diagnosis. Each of the four areas is categorized in terms of the AI techniques used: genetic algorithms, case-based reasoning, knowledge-based systems, fuzzy logic and hybrid techniques. The trends over the last decade are identified, discussed with respect to expected trends and directions for future work suggested

Bridges Structural Health Monitoring and Deterioration Detection Synthesis of Knowledge and Technology

INE/AUTC 10.0

Integrating Machine Learning Paradigms for Predictive Maintenance in the Fourth Industrial Revolution era

In the last decade, manufacturing companies have been facing two significant challenges. First, digitalization imposes adopting Industry 4.0 technologies and allows creating smart, connected, self-aware, and self-predictive factories. Second, the attention on sustainability imposes to evaluate and reduce the impact of the implemented solutions from economic and social points of view. In manufacturing companies, the maintenance of physical assets assumes a critical role. Increasing the reliability and the availability of production systems leads to the minimization of systems’ downtimes; In addition, the proper system functioning avoids production wastes and potentially catastrophic accidents. Digitalization and new ICT technologies have assumed a relevant role in maintenance strategies. They allow assessing the health condition of machinery at any point in time. Moreover, they allow predicting the future behavior of machinery so that maintenance interventions can be planned, and the useful life of components can be exploited until the time instant before their fault. This dissertation provides insights on Predictive Maintenance goals and tools in Industry 4.0 and proposes a novel data acquisition, processing, sharing, and storage framework that addresses typical issues machine producers and users encounter. The research elaborates on two research questions that narrow down the potential approaches to data acquisition, processing, and analysis for fault diagnostics in evolving environments. The research activity is developed according to a research framework, where the research questions are addressed by research levers that are explored according to research topics. Each topic requires a specific set of methods and approaches; however, the overarching methodological approach presented in this dissertation includes three fundamental aspects: the maximization of the quality level of input data, the use of Machine Learning methods for data analysis, and the use of case studies deriving from both controlled environments (laboratory) and real-world instances

Fault analysis using state-of-the-art classifiers

Fault Analysis is the detection and diagnosis of malfunction in machine operation or process control. Early fault analysis techniques were reserved for high critical plants such as nuclear or chemical industries where abnormal event prevention is given utmost importance. The techniques developed were a result of decades of technical research and models based on extensive characterization of equipment behavior. This requires in-depth knowledge of the system and expert analysis to apply these methods for the application at hand. Since machine learning algorithms depend on past process data for creating a system model, a generic autonomous diagnostic system can be developed which can be used for application in common industrial setups. In this thesis, we look into some of the techniques used for fault detection and diagnosis multi-class and one-class classifiers. First we study Feature Selection techniques and the classifier performance is analyzed against the number of selected features. The aim of feature selection is to reduce the impact of irrelevant variables and to reduce computation burden on the learning algorithm. We introduce the feature selection algorithms as a literature survey. Only few algorithms are implemented to obtain the results. Fault data from a Radio Frequency (RF) generator is used to perform fault detection and diagnosis. Comparison between continuous and discrete fault data is conducted for the Support Vector Machines (SVM) and Radial Basis Function Network (RBF) classifiers. In the second part we look into one-class classification techniques and their application to fault detection. One-class techniques were primarily developed to identify one class of objects from all other possible objects. Since all fault occurrences in a system cannot be simulated or recorded, one-class techniques help in identifying abnormal events. We introduce four one-class classifiers and analyze them using Receiver-Operating Characteristic (ROC) curve. We also develop a feature extraction method for the RF generator data which is used to obtain results for one-class classifiers and Radial Basis Function Network two class classification. To apply these techniques for real-time verification, the RIT Fault Prediction software is built. LabView environment is used to build a basic data management and fault detection using Radial Basis Function Network. This software is stand alone and acts as foundation for future implementations