Failure Diagnosis and Prognosis of Safety Critical Systems: Applications in Aerospace Industries

Many safety-critical systems such as aircraft, space crafts, and large power plants are required to operate in a reliable and efficient working condition without any performance degradation. As a result, fault diagnosis and prognosis (FDP) is a research topic of great interest in these systems. FDP systems attempt to use historical and current data of a system, which are collected from various measurements to detect faults, diagnose the types of possible failures, predict and manage failures in advance. This thesis deals with FDP of safety-critical systems. For this purpose, two critical systems including a multifunctional spoiler (MFS) and hydro-control value system are considered, and some challenging issues from the FDP are investigated. This research work consists of three general directions, i.e., monitoring, failure diagnosis, and prognosis. The proposed FDP methods are based on data-driven and model-based approaches. The main aim of the data-driven methods is to utilize measurement data from the system and forecast the remaining useful life (RUL) of the faulty components accurately and efficiently. In this regard, two dierent methods are developed. A modular FDP method based on a divide and conquer strategy is presented for the MFS system. The modular structure contains three components:1) fault diagnosis unit, 2) failure parameter estimation unit and 3) RUL unit. The fault diagnosis unit identifies types of faults based on an integration of neural network (NN) method and discrete wavelet transform (DWT) technique. Failure parameter estimation unit observes the failure parameter via a distributed neural network. Afterward, the RUL of the system is predicted by an adaptive Bayesian method. In another work, an innovative data-driven FDP method is developed for hydro-control valve systems. The idea is to use redundancy in multi-sensor data information and enhance the performance of the FDP system. Therefore, a combination of a feature selection method and support vector machine (SVM) method is applied to select proper sensors for monitoring of the hydro-valve system and isolate types of fault. Then, adaptive neuro-fuzzy inference systems (ANFIS) method is used to estimate the failure path. Similarly, an online Bayesian algorithm is implemented for forecasting RUL. Model-based methods employ high-delity physics-based model of a system for prognosis task. In this thesis, a novel model-based approach based on an integrated extended Kalman lter (EKF) and Bayesian method is introduced for the MFS system. To monitor the MFS system, a residual estimation method using EKF is performed to capture the progress of the failure. Later, a transformation is utilized to obtain a new measure to estimate the degradation path (DP). Moreover, the recursive Bayesian algorithm is invoked to predict the RUL. Finally, relative accuracy (RA) measure is utilized to assess the performance of the proposed methods

Test platform for electronic control units of high-performance safety-critical multi actuator systems

In this paper we are mostly concerned with the problem of testing electronic control units of synchronized electric power actuators. This task is particularly complex for safety critical applications, where it is crucial that the control system properly reacts in response to the faults, that are hard to reproduce and verify. A cost-effective flexible and reconfigurable test platform is proposed, discussing its architecture and implementation. The proposed system facilitates the phase of definition and development of the electronic control unit, allowing the interfacing towards both hydraulic and electromechanical actuators, and having a high flexibility as regards the I/O signals. Some results, obtained during the laboratory test activity, are also presented

Optimized state feedback regulation of 3DOF helicopter system via extremum seeking

In this paper, an optimized state feedback regulation of a 3 degree of freedom (DOF) helicopter is designed via extremum seeking (ES) technique. Multi-parameter ES is applied to optimize the tracking performance via tuning State Vector Feedback with Integration of the Control Error (SVFBICE). Discrete multivariable version of ES is developed to minimize a cost function that measures the performance of the controller. The cost function is a function of the error between the actual and desired axis positions. The controller parameters are updated online as the optimization takes place. This method significantly decreases the time in obtaining optimal controller parameters. Simulations were conducted for the online optimization under both fixed and varying operating conditions. The results demonstrate the usefulness of using ES for preserving the maximum attainable performance

The Application of Artificial Intelligence in Project Management Research: A Review

The field of artificial intelligence is currently experiencing relentless growth, with innumerable models emerging in the research and development phases across various fields, including science, finance, and engineering. In this work, the authors review a large number of learning techniques aimed at project management. The analysis is largely focused on hybrid systems, which present computational models of blended learning techniques. At present, these models are at a very early stage and major efforts in terms of development is required within the scientific community. In addition, we provide a classification of all the areas within project management and the learning techniques that are used in each, presenting a brief study of the different artificial intelligence techniques used today and the areas of project management in which agents are being applied. This work should serve as a starting point for researchers who wish to work in the exciting world of artificial intelligence in relation to project leadership and management

Fault-detection on an experimental aircraft fuel rig using a Kalman filter-based FDI screen

Reliability is an important issue across industry. This is due to a number of drivers such as the requirement of high safety levels within industries such as aviation, the need for mission success with military equipment, or to avoid monetary losses (due to unplanned outage) within the process and many other industries. The application of fault detection and identification helps to identify the presence of faults to improve mission success or increase up-time of plant equipment. Implementation of such systems can take the form of pattern recognition, statistical and geometric classifiers, soft computing methods or complex model based methods. This study deals with the latter, and focuses on a specific type of model, the Kalman filter. The Kalman filter is an observer which estimates the states of a system, i.e. the physical variables, based upon its current state and knowledge of its inputs. This relies upon the creation of a mathematical model of the system in order to predict the outputs of the system at any given time. Feedback from the plant corrects minor deviation between the system and the Kalman filter model. Comparison between this prediction of outputs and the real output provides the indication of the presence of a fault. On systems with several inputs and outputs banks of these filters can used in order to detect and isolate the various faults that occur in the process and its sensors and actuators. The thesis examines the application of the diagnostic techniques to a laboratory scale aircraft fuel system test-rig. The first stage of the research project required the development of a mathematical model of the fuel rig. Test data acquired by experiment is used to validate the system model against the fuel rig. This nonlinear model is then simplified to create several linear state space models of the fuel rig. These linear models are then used to develop the Kalman filter Fault Detection and Identification (FDI) system by application of appropriate tuning of the Kalman filter gains and careful choice of residual thresholds to determine fault condition boundaries and logic to identify the location of the fault. Additional performance enhancements are also achieved by implementation of statistical evaluation of the residual signal produced and by automatic threshold calculation. The results demonstrate the positive capture of a fault condition and identification of its location in an aircraft fuel system test-rig. The types of fault captured are hard faults such sensor malfunction and actuator failure which provide great deviation of the residual signals and softer faults such as performance degradation and fluid leaks in the tanks and pipes. Faults of a smaller magnitude are captured very well albeit within a larger time range. The performance of the Fault Diagnosis and Identification was further improved by the implementation of statistically evaluating the residual signal and by the development of automatic threshold determination. Identification of the location of the fault is managed by the use of mapping the possible fault permutations and the Kalman filter behaviour, this providing full discrimination between any faults present. Overall the Kalman filter based FDI developed provided positive results in capturing and identifying a system fault on the test-rig

Contributions to industrial process condition forecasting applied to copper rod manufacturing process

Ensuring reliability and robustness of operation is one of the main concerns in industrial anufacturing processes , dueto the ever-increasing demand for improvements over the cost and quality ofthe processes outcome. In this regard , a deviation from the nominal operating behaviours implies a divergence from the optimal condition specification, anda misalignment from the nominal product quality, causing a critica! loss of potential earnings . lndeed, since a decade ago, the industrial sector has been carried out a significant effortAsegurar la fiabilidad y la robustez es uno de los principales objetivos en la monitorización de los procesos industriales, ya que estos cada vez se encuentran sometidos a demandas de producción más elevadas a la vez que se deben bajar costes de fabricación manteniendo la calidad del producto final. En este sentido, una desviación de la operación del proceso implica una divergencia de los parámetros óptimos preestablecidos, lo que conlleva a una desviación respecto la calidad nominal del producto final, causando así un rechazo de dicho producto y una perdida en costes para la empresa. De hecho, tanto es así, que desde hace más de una década el sector industrial ha dedicado un esfuerzo considerable a la implantación de metodologías de monitorización inteligente. Dichos métodos son capaces extraer información respecto a la condición de las diferentes maquinarias y procesos involucrados en el proceso de fabricación. No obstante, esta información extraída corresponde al estado actual del proceso. Por lo que obtener información respecto a la condición futura de dicho proceso representa una mejora significativa para poder ganar tiempo de respuesta para la detección y corrección de desviaciones en la operación de dicho proceso. Por lo tanto, la combinación del conocimiento futuro del comportamiento del proceso con la consecuente evaluación de la condición del mismo, es un objetivo a cumplir para la definición de las nuevas generaciones de sistemas de monitorización de procesos industriales. En este sentido, la presente tesis tiene como objetivo la propuesta de metodologías para evaluar la condición, actual y futura, de procesos industriales. Dicha metodología debe estimar la condición de forma fiable y con una alta resolución. Por lo tanto, en esta tesis se pretende extraer la información de la condición futura a partir de un modelado, basado en series temporales, de las señales críticas del proceso, para después, en base a enfoques no lineales de preservación de la topología, fusionar dichas señales proyectadas a futuro para conocer la condición. El rendimiento y la bondad de las metodologías propuestas en la tesis han sido validadas mediante su aplicación en un proceso industrial real, concretamente, con datos de una planta de fabricación de alambrón de cobre