DEVELOPMENT OF DIAGNOSTIC AND PROGNOSTIC METHODOLOGIES FOR ELECTRONIC SYSTEMS BASED ON MAHALANOBIS DISTANCE

Diagnostic and prognostic capabilities are one aspect of the many interrelated and complementary functions in the field of Prognostic and Health Management (PHM). These capabilities are sought after by industries in order to provide maximum operational availability of their products, maximum usage life, minimum periodic maintenance inspections, lower inventory cost, accurate tracking of part life, and no false alarms. Several challenges associated with the development and implementation of these capabilities are the consideration of a system's dynamic behavior under various operating environments; complex system architecture where the components that form the overall system have complex interactions with each other with feed-forward and feedback loops of instructions; the unavailability of failure precursors; unseen events; and the absence of unique mathematical techniques that can address fault and failure events in various multivariate systems. The Mahalanobis distance methodology distinguishes multivariable data groups in a multivariate system by a univariate distance measure calculated from the normalized value of performance parameters and their correlation coefficients. The Mahalanobis distance measure does not suffer from the scaling effect--a situation where the variability of one parameter masks the variability of another parameter, which happens when the measurement ranges or scales of two parameters are different. A literature review showed that the Mahalanobis distance has been used for classification purposes. In this thesis, the Mahalanobis distance measure is utilized for fault detection, fault isolation, degradation identification, and prognostics. For fault detection, a probabilistic approach is developed to establish threshold Mahalanobis distance, such that presence of a fault in a product can be identified and the product can be classified as healthy or unhealthy. A technique is presented to construct a control chart for Mahalanobis distance for detecting trends and biasness in system health or performance. An error function is defined to establish fault-specific threshold Mahalanobis distance. A fault isolation approach is developed to isolate faults by identifying parameters that are associated with that fault. This approach utilizes the design-of-experiment concept for calculating residual Mahalanobis distance for each parameter (i.e., the contribution of each parameter to a system's health determination). An expected contribution range for each parameter estimated from the distribution of residual Mahalanobis distance is used to isolate the parameters that are responsible for a system's anomalous behavior. A methodology to detect degradation in a system's health using a health indicator is developed. The health indicator is defined as the weighted sum of a histogram bin's fractional contribution. The histogram's optimal bin width is determined from the number of data points in a moving window. This moving window approach is utilized for progressive estimation of the health indicator over time. The health indicator is compared with a threshold value defined from the system's healthy data to indicate the system's health or performance degradation. A symbolic time series-based health assessment approach is developed. Prognostic measures are defined for detecting anomalies in a product and predicting a product's time and probability of approaching a faulty condition. These measures are computed from a hidden Markov model developed from the symbolic representation of product dynamics. The symbolic representation of a product's dynamics is obtained by representing a Mahalanobis distance time series in symbolic form. Case studies were performed to demonstrate the capability of the proposed methodology for real time health monitoring. Notebook computers were exposed to a set of environmental conditions representative of the extremes of their life cycle profiles. The performance parameters were monitored in situ during the experiments, and the resulting data were used as a training dataset. The dataset was also used to identify specific parameter behavior, estimate correlation among parameters, and extract features for defining a healthy baseline. Field-returned computer data and data corresponding to artificially injected faults in computers were used as test data

Integration of mahalanobis-taguchi system and activity based costing in decision making for remanufacturing

Classifying components at the end of life (EOL) into remanufacture, repair or dispose is still a major concern to automotive industries. Prior to this study, no specific approach is reported as a guide line to determine critical crankpins that justifying economical remanufacturing process. Traditional cost accounting (TCA) has been used widely by remanufacturing industries but this is not a good measure of estimating the actual manufacturing costs per unit as compared to activity based costing (ABC). However, the application of ABC method in estimating remanufactured cost is rarely reported. These issues were handled separately without a proper integration to make remanufacturing decision which frequently results into uneconomical operating cost and finally the decision becomes less accurate. The aim of this work is to develop a suitable pattern recognition method for classifying crankshaft into three different EOL groups and subsequently evaluates the critical and non-critical crankpins of the used crankshaft using Mahalanobis-Taguchi System (MTS). A remanufacturability assessment technique was developed using Microsoft Excel spreadsheet on pattern recognition and critical crankpins evaluation, and finally integrates these information into a similar spreadsheet with ABC to make decision whether the crankshaft is to be remanufactured, repaired or disposed. The developed scatter diagram was able to recognize group pattern of EOL crankshaft which later was successfully used to determine critical crankpins required for remanufacturing process. The proposed method can serve as a useful approach to the remanufacturing industries for systematically evaluate and decide EOL components for further processing. Case study on six engine models, the result shows that three engines can be securely remanufactured at above 40% profit margin while another two engines are still viable to remanufacture but with less profit margin. In contrast, only two engines can be securely remanufactured due overcharge when using TCA. This inaccuracy affects significantly the overall remanufacturing activities and revenue of the industry. In conclusion, the proposed integration on pattern recognition, parameter evaluation and costing assists the decision making process to effectively remanufacture EOL automotive components as confirmed by Head of workshop of Motor Teknologi Industri Sdn. Bhd

Data classification and forecasting using the Mahalanobis-Taguchi method

Classification and forecasting are useful concepts in the field of condition monitoring. Condition monitoring refers to the analysis and monitoring of system characteristics to understand and identify deviations from normal operating conditions. This can be performed for prediction, diagnosis, or prognosis or a combination of any these purposes. Fault identification and diagnosis are usually achieved through data classification, while forecasting methods are usually used to accomplish the prediction objective. Data gathered from monitoring systems often consists of multiple multivariate time series and is fed into a model for data analysis using various techniques. One of the data analysis techniques used is the Mahalanobis-Taguchi strategy (MTS) because of its suitability for multivariate data analysis. MTS provides a means of extracting information in a multidimensional system by integrating information from different variables into a single composite metric. MTS is used to conduct analysis on the measurement parameters and seeks a correlation with the result while also seeking to optimize the analysis by identifying variables of importance strongly correlated with a defect or fault occurrence. This research presents the application of a MTS based system for predicting faults in heavy duty vehicles and the application of MTS in a multiclass classification problem. The benefits and practicality of the methodology in industrial applications are demonstrated through the use of real world data and discussion of results. --Abstract, page iv

Sensor data-based decision making

Increasing globalization and growing industrial system complexity has amplified the interest in the use of information provided by sensors as a means of improving overall manufacturing system performance and maintainability. However, utilization of sensors can only be effective if the real-time data can be integrated into the necessary business processes, such as production planning, scheduling and execution systems. This integration requires the development of intelligent decision making models that can effectively process the sensor data into information and suggest appropriate actions. To be able to improve the performance of a system, the health of the system also needs to be maintained. In many cases a single sensor type cannot provide sufficient information for complex decision making including diagnostics and prognostics of a system. Therefore, a combination of sensors should be used in an integrated manner in order to achieve desired performance levels. Sensor generated data need to be processed into information through the use of appropriate decision making models in order to improve overall performance. In this dissertation, which is presented as a collection of five journal papers, several reactive and proactive decision making models that utilize data from single and multi-sensor environments are developed. The first paper presents a testbed architecture for Auto-ID systems. An adaptive inventory management model which utilizes real-time RFID data is developed in the second paper. In the third paper, a complete hardware and inventory management solution, which involves the integration of RFID sensors into an extremely low temperature industrial freezer, is presented. The last two papers in the dissertation deal with diagnostic and prognostic decision making models in order to assure the healthy operation of a manufacturing system and its components. In the fourth paper a Mahalanobis-Taguchi System (MTS) based prognostics tool is developed and it is used to estimate the remaining useful life of rolling element bearings using data acquired from vibration sensors. In the final paper, an MTS based prognostics tool is developed for a centrifugal water pump, which fuses information from multiple types of sensors in order to take diagnostic and prognostics decisions for the pump and its components --Abstract, page iv

Prognostics and health monitoring of high power LED

Prognostics is seen as a key component of health usage monitoring systems, where prognostics algorithms can both detect anomalies in the behaviour/performance of a micro-device/system, and predict its remaining useful life when subjected to monitored operational and environmental conditions. Light Emitting Diodes (LEDs) are optoelectronic micro-devices that are now replacing traditional incadescent and fluorescent lighting, as they have many advantages including higher reliability, greater energy efficiency, long life time and faster switching speed. For some LED applications there is a requirement to monitor the health of LED lighting systems and predict when failure is likely to occur. This is very important in the case of safety critical and emergency applications. This paper provides both experimental and theoretical results that demonstrate the use of prognostics and health monitoring techniques for high power LEDs subjected to harsh operating conditions

Classification of crankshaft remanufacturing using Mahalanobis-Taguchi system

Remanufacturing is a process of returning a used product to at least its original performance with a warranty that is equivalent or better than that of a newly manufactured product. During a preliminary inspection on remanufacturing companies, it was found that there is no end life for crankshafts in terms of classifying it either to remanufacture, repair or reject due to limited information provided by the original equipment manufacturer. The manufacturer did not provide any information on the annual quantity produced and their specifications to the remanufacturing company for the purpose of referencing. Eventually, the distinctiveness of the remanufactured crankshaft from the original cannot be measured. Thus, the aim of this work is to classify crankshafts' end life into recovery operations based on the Mahalanobis-Taguchi System. The crankpin diameter of six engine models were measured in order to develop a scale that represents their population in a scatter diagram. It was found that on the diagram of each engine model, the left distributions from the center point belong to rejected crankshafts, the right distributions belong to re-manufacturable crankshafts, and the upper distributions belong to the repairable crankshafts. The developed scale is believed to be able to help remanufacturers instantaneously identify and match any unknown model crankshafts to its right category. The Ministry of International Trade & Industry (MITI) has established a remanufacturing policy under RMK11 and put in efforts to encourage Malaysians to venture into the remanufacturing business. Thus, this model will help the industry to understand and formulate their decision-making to sustain the end of life of their products

A COMPARISON BETWEEN DATA-DRIVEN AND PHYSICS OF FAILURE PHM APPROACHES FOR SOLDER JOINT FATIGUE

Prognostics and systems health management technology is an enabling discipline of technologies and methods with the potential of solving reliability problems that have been manifested due to complexities in design, manufacturing, environmental and operational use conditions, and maintenance. Over the past decade, research has been conducted in PHM to provide benefits such as advance warning of failures, enable forecasted maintenance, improve system qualification, extend system life, and diagnose intermittent failures that can lead to field failure returns exhibiting no-fault-found symptoms. While there are various methods to perform prognostics, including model-based and data-driven methods, these methods have some key disadvantages. This thesis presents a fusion prognostics approach, which combines or ―fuses together‖ the model based and data-driven approaches, to enable increasingly better estimates of remaining useful life. A case study using an electronics system to illustrate a step by step implementation of the fusion approach is also presented. The various benefits of the fusion approach and suggestions for future work are included

Méthodes statistiques de détection d’observations atypiques pour des données en grande dimension

La détection d’observations atypiques de manière non-supervisée est un enjeu crucial dans la pratique de la statistique. Dans le domaine de la détection de défauts industriels, cette tâche est d’une importance capitale pour assurer une production de haute qualité. Avec l’accroissement exponentiel du nombre de mesures effectuées sur les composants électroniques, la problématique de la grande dimension se pose lors de la recherche d’anomalies. Pour relever ce challenge, l’entreprise ippon innovation, spécialiste en statistique industrielle et détection d’anomalies, s’est associée au laboratoire de recherche TSE-R en finançant ce travail de thèse. Le premier chapitre commence par présenter le contexte du contrôle de qualité et les différentes procédures déjà mises en place, principalement dans les entreprises de semi-conducteurs pour l’automobile. Comme ces pratiques ne répondent pas aux nouvelles attentes requises par le traitement de données en grande dimension, d’autres solutions doivent être envisagées. La suite du chapitre résume l’ensemble des méthodes multivariées et non supervisées de détection d’observations atypiques existantes, en insistant tout particulièrement sur celles qui gèrent des données en grande dimension. Le Chapitre 2 montre théoriquement que la très connue distance de Mahalanobis n’est pas adaptée à la détection d’anomalies si celles-ci sont contenues dans un sous-espace de petite dimension alors que le nombre de variables est grand.Dans ce contexte, la méthode Invariant Coordinate Selection (ICS) est alors introduite comme une alternative intéressante à la mise en évidence de la structure des données atypiques. Une méthodologie pour sélectionner seulement les composantes d’intérêt est proposée et ses performances sont comparées aux standards habituels sur des simulations ainsi que sur des exemples réels industriels. Cette nouvelle procédure a été mise en oeuvre dans un package R, ICSOutlier, présenté dans le Chapitre 3 ainsi que dans une application R shiny (package ICSShiny) qui rend son utilisation plus simple et plus attractive.Une des conséquences directes de l’augmentation du nombre de dimensions est la singularité des estimateurs de dispersion multivariés, dès que certaines variables sont colinéaires ou que leur nombre excède le nombre d’individus. Or, la définition d’ICS par Tyler et al. (2009) se base sur des estimateurs de dispersion définis positifs. Le Chapitre 4 envisage différentes pistes pour adapter le critère d’ICS et investigue de manière théorique les propriétés de chacune des propositions présentées. La question de l’affine invariance de la méthode est en particulier étudiée. Enfin le dernier chapitre, se consacre à l’algorithme développé pour l’entreprise. Bien que cet algorithme soit confidentiel, le chapitre donne les idées générales et précise les challenges relevés, notamment numériques.The unsupervised outlier detection is a crucial issue in statistics. More specifically, in the industrial context of fault detection, this task is of great importance for ensuring a high quality production. With the exponential increase in the number of measurements on electronic components, the concern of high dimensional data arises in the identification of outlying observations. The ippon innovation company, an expert in industrial statistics and anomaly detection, wanted to deal with this new situation. So, it collaborated with the TSE-R research laboratory by financing this thesis work. The first chapter presents the quality control context and the different procedures mainly used in the automotive industry of semiconductors. However, these practices do not meet the new expectations required in dealing with high dimensional data, so other solutions need to be considered. The remainder of the chapter summarizes unsupervised multivariate methods for outlier detection, with a particular emphasis on those dealing with high dimensional data. Chapter 2 demonstrates that the well-known Mahalanobis distance presents some difficulties to detect the outlying observations that lie in a smaller subspace while the number of variables is large. In this context, the Invariant Coordinate Selection (ICS) method is introduced as an interesting alternative for highlighting the structure of outlierness. A methodology for selecting only the relevant components is proposed. A simulation study provides a comparison with benchmark methods. The performance of our proposal is also evaluated on real industrial data sets. This new procedure has been implemented in an R package, ICSOutlier, presented in Chapter 3, and in an R shiny application (package ICSShiny) that makes it more user-friendly. When the number of dimensions increases, the multivariate scatter matrices turn out to be singular as soon as some variables are collinear or if their number exceeds the number of individuals. However, in the presentation of ICS by Tyler et al. (2009), the scatter estimators are defined as positive definite matrices. Chapter 4 proposes three different ways for adapting the ICS method to singular scatter matrices and theoretically investigates their properties. The question of affine invariance is analyzed in particular. Finally, the last chapter is dedicated to the algorithm developed for the company. Although the algorithm is confidential, the chapter presents the main ideas and the challenges, mostly numerical, encountered during its development

Prognostics and health management of light emitting diodes

Prognostics is an engineering process of diagnosing, predicting the remaining useful life and estimating the reliability of systems and products. Prognostics and Health Management (PHM) has emerged in the last decade as one of the most efficient approaches in failure prevention, reliability estimation and remaining useful life predictions of various engineering systems and products. Light Emitting Diodes (LEDs) are optoelectronic micro-devices that are now replacing traditional incandescent and fluorescent lighting, as they have many advantages including higher reliability, greater energy efficiency, long life time and faster switching speed. Even though LEDs have high reliability and long life time, manufacturers and lighting systems designers still need to assess the reliability of LED lighting systems and the failures in the LED. This research provides both experimental and theoretical results that demonstrate the use of prognostics and health monitoring techniques for high power LEDs subjected to harsh operating conditions. Data driven, model driven and fusion prognostics approaches are developed to monitor and identify LED failures, based on the requirement for the light output power. The approaches adopted in this work are validated and can be used to assess the life of an LED lighting system after their deployment based on the power of the light output emitted. The data driven techniques are only based on monitoring selected operational and performance indicators using sensors whereas the model driven technique is based on sensor data as well as on a developed empirical model. Fusion approach is also developed using the data driven and the model driven approaches to the LED. Real-time implementation of developed approaches are also investigated and discussed

Diagnostic and prognostic analysis tools for monitoring degradation in aged structures

This research addresses the problem of prolonging the life of aged structures of historical value that have already outlived their original designed lives many times. While a lot of research has been carried out in the field of structural monitoring, diagnostics and prognostics for high tech industries, this is not the case for historical aged structures. Currently most maintenance projects for aged structures have focused on the instrumentation and diagnostic techniques required to detect any damage with a certain degree of success. This research project involved the development of diagnostic and prognostic tools to be used for monitoring and predicting the ‘health’ of aged structures. The diagnostic and prognostic tools have been developed for the monitoring of Cutty Sark iron structures as a first application. The concept of canary and parrot sensor devices are developed where canary devices are small, accelerated devices, which will fail according to similar failure mechanisms occurring in an aged structures and parrot devices are designed to fail at the same rate as the structure, thus mimicking the structure. The model-driven prognostic tool uses a Physics-of-Failure (PoF) model to predict remaining life of a structure. It uses a corrosion model based on the decrease in corrosion rate over time to predict remaining life of an aged iron structures. The data-driven diagnostic tool developed uses Mahalanobis Distance analysis to detect anomalies in the behaviour of a structure. Bayesian Network models are then used as a fusion method, integrating remaining life predictions from the model-driven prognostic tool with information of possible anomalies from data-driven diagnostic tool to provide a probability distribution of predicted remaining life. The diagnostics and prognostic tools are validated and tested through demonstration example and experimental tests. This research primarily looks at applying diagnostic and prognostic technologies used in high-tech industries to aged iron structures. In order to achieve this, the model-driven and data-driven techniques commonly used had to be adapted taking into consideration the particular constraints of monitoring and maintaining aged structures. The fusion technique developed is a novel approach for prognostics for aged structures and provides the flexibility often needed for diagnostic and prognostic tools