Novel deep cross-domain framework for fault diagnosis or rotary machinery in prognostics and health management

Improving the reliability of engineered systems is a crucial problem in many applications in various engineering fields, such as aerospace, nuclear energy, and water declination industries. This requires efficient and effective system health monitoring methods, including processing and analyzing massive machinery data to detect anomalies and performing diagnosis and prognosis. In recent years, deep learning has been a fast-growing field and has shown promising results for Prognostics and Health Management (PHM) in interpreting condition monitoring signals such as vibration, acoustic emission, and pressure due to its capacity to mine complex representations from raw data. This doctoral research provides a systematic review of state-of-the-art deep learning-based PHM frameworks, an empirical analysis on bearing fault diagnosis benchmarks, and a novel multi-source domain adaptation framework. It emphasizes the most recent trends within the field and presents the benefits and potentials of state-of-the-art deep neural networks for system health management. Besides, the limitations and challenges of the existing technologies are discussed, which leads to opportunities for future research. The empirical study of the benchmarks highlights the evaluation results of the existing models on bearing fault diagnosis benchmark datasets in terms of various performance metrics such as accuracy and training time. The result of the study is very important for comparing or testing new models. A novel multi-source domain adaptation framework for fault diagnosis of rotary machinery is also proposed, which aligns the domains in both feature-level and task-level. The proposed framework transfers the knowledge from multiple labeled source domains into a single unlabeled target domain by reducing the feature distribution discrepancy between the target domain and each source domain. Besides, the model can be easily reduced to a single-source domain adaptation problem. Also, the model can be readily updated to unsupervised domain adaptation problems in other fields such as image classification and image segmentation. Further, the proposed model is modified with a novel conditional weighting mechanism that aligns the class-conditional probability of the domains and reduces the effect of irrelevant source domain which is a critical issue in multi-source domain adaptation algorithms. The experimental verification results show the superiority of the proposed framework over state-of-the-art multi-source domain-adaptation models

AI-driven Maintenance Support for Downhole Tools and Electronics Operated in Dynamic Drilling Environments

Downhole tools are complex electro-mechanical systems that perform critical functions in drilling operations. The electronics within these systems provide vital support, such as control, navigation and front-end data analysis from sensors. Due to the extremely challenging operating conditions, namely high pressure, temperature and vibrational forces, electronics can be subjected to complex failure modes and incur operational downtime. A novel Artificial Intelligence (AI)-driven Condition Based Maintenance (CBM) support system is presented, combining Bottom Hole Assembly (BHA) data with Big Data Analytics (BDA). The key objective of this system is to reduce maintenance costs along with an overall improvement of fleet reliability. As evidenced within the literature review, the application of AI methods to downhole tool maintenance is underrepresented in terms of oil and gas application. We review the BHA electronics failure modes and propose a methodology for BHA-Printed Component Board Assemblies (PCBA) CBM. We compare the results of a Random Forest Classifier (RFC) and a XGBoost Classifier trained on BHA electronics memory data cumulated during 208 missions over a 6 months period, achieving an accuracy of 90 % for predicting PCBA failure. These results are extended into a commercial analysis examining various scenarios of infield failure costs and fleet reliability levels. The findings of this paper demonstrate the value of the BHA-PCBA CBM framework by providing accurate prognosis of operational equipment health leading to reduced costs, minimised Non-Productive Time (NPT) and increased operational reliability

Artificial Intelligence Supported EV Electric Powertrain for Safety Improvement

As an environmentally friendly transport option, electric vehicles (EVs) are endowed with the characteristics of low fossil energy consumption and low pollutant emissions. In today's growing market share of EVs, the safety and reliability of the powertrain system will be directly related to the safety of human life. Reliability problems of EV powertrains may occur in any power electronic (PE) component and mechanical part, both sudden and cumulative. These faults in different locations and degrees will continuously threaten the life of drivers and pedestrians, bringing irreparable consequences. Therefore, monitoring and predicting the real-time health status of EV powertrain is a high-priority, arduous and challenging task. The purposes of this study are to develop AI-supported effective safety improvement techniques for EV powertrains. In the first place, a literature review is carried out to illustrate the up-to-date AI applications for solving condition monitoring and fault detection issues of EV powertrains, where recent case studies between conventional methods and AI-based methods in EV applications are compared and analysed. On this ground this study, then, focuses on the theories and techniques concerning this topic so as to tackle different challenges encountered in the actual applications. In detail, first, as for diagnosing the bearing system in the earlier fault period, a novel inferable deep distilled attention network is designed to detect multiple bearing faults. Second, a deep learning and simulation driven approach that combines the domain-adversarial neural network and the lumped-parameter thermal network (LPTN) is proposed for achieve IPMSM permanent magnet temperature estimation work. Finally, to ensure the use safety of the IGBT module, deep learning -based IGBT modules’ double pulse test (DPT) efficiency enhancement is proposed and achieved via multimodal fusion networks and graph convolution networks

AI-Driven Maintenance Support for Downhole Tools and Electronics Operated in Dynamic Drilling Environments

Downhole tools are complex electro-mechanical systems that perform critical functions in drilling operations. The electronics within these systems provide vital support, such as control, navigation and front-end data analysis from sensors. Due to the extremely challenging operating conditions, namely high pressure, temperature and vibrational forces, electronics can be subjected to complex failure modes and incur operational downtime. A novel Artificial Intelligence (AI)-driven Condition Based Maintenance (CBM) support system is presented, combining Bottom Hole Assembly (BHA) data with Big Data Analytics (BDA). The key objective of this system is to reduce maintenance costs along with an overall improvement of fleet reliability. As evidenced within the literature review, the application of AI methods to downhole tool maintenance is underrepresented in terms of oil and gas application. We review the BHA electronics failure modes and propose a methodology for BHA-Printed Component Board Assemblies (PCBA) CBM. We compare the results of a Random Forest Classifier (RFC) and a XGBoost Classifier trained on BHA electronics memory data cumulated during 208 missions over a 6 months period, achieving an accuracy of 90 % for predicting PCBA failure. These results are extended into a commercial analysis examining various scenarios of infield failure costs and fleet reliability levels. The findings of this paper demonstrate the value of the BHA-PCBA CBM framework by providing accurate prognosis of operational equipment health leading to reduced costs, minimised Non-Productive Time (NPT) and increased operational reliability

Shallow neural networks for autonomous robots

The use of Neural Networks (NNs) in modern applications is already well established thanks to the technological advancements in processing units and Deep Learning (DL), as well as the availability of deployment frameworks and services. However, the embedding of these methods in robotic systems is problematic when it comes to field operations. The use of Graphics Processing Units (GPUs) for such networks requires high amounts of power which would lead to shortened operational times. This is not desired since autonomous robots already need to manage their power supply to accommodate the lengths of their missions which can extend from hours to days. While external processing is possible, real-time monitoring can become unfeasible where delays are present. This also applies to autonomous robots that are deployed for underwater or space missions. For these reasons, there is a requirement for shallow but robust NN-based solutions that enhance the autonomy of a robot. This dissertation focuses on the design and meticulous parametrization complemented by methods that explain hyper-parameter importance. This is performed in the context of different settings and problems for autonomous robots in field operations. The contribution of this thesis comes in the form of autonomy augmentation for robots through shallow NNs that can potentially be embedded in future systems carrying NN processing units. This is done by implementing neural architectures that use sensor data to extract representations for event identification and learn patterns for event anticipation. This work harnesses Long Short-Term Memory networks (LSTMs) as the underpinning framework for time series representation and interpretation. This has been tested in three significant problems found in field operations: hardware malfunction classification, survey trajectory classification and hazardous event forecast and detection

Internet of Underwater Things and Big Marine Data Analytics -- A Comprehensive Survey

The Internet of Underwater Things (IoUT) is an emerging communication ecosystem developed for connecting underwater objects in maritime and underwater environments. The IoUT technology is intricately linked with intelligent boats and ships, smart shores and oceans, automatic marine transportations, positioning and navigation, underwater exploration, disaster prediction and prevention, as well as with intelligent monitoring and security. The IoUT has an influence at various scales ranging from a small scientific observatory, to a midsized harbor, and to covering global oceanic trade. The network architecture of IoUT is intrinsically heterogeneous and should be sufficiently resilient to operate in harsh environments. This creates major challenges in terms of underwater communications, whilst relying on limited energy resources. Additionally, the volume, velocity, and variety of data produced by sensors, hydrophones, and cameras in IoUT is enormous, giving rise to the concept of Big Marine Data (BMD), which has its own processing challenges. Hence, conventional data processing techniques will falter, and bespoke Machine Learning (ML) solutions have to be employed for automatically learning the specific BMD behavior and features facilitating knowledge extraction and decision support. The motivation of this paper is to comprehensively survey the IoUT, BMD, and their synthesis. It also aims for exploring the nexus of BMD with ML. We set out from underwater data collection and then discuss the family of IoUT data communication techniques with an emphasis on the state-of-the-art research challenges. We then review the suite of ML solutions suitable for BMD handling and analytics. We treat the subject deductively from an educational perspective, critically appraising the material surveyed.Comment: 54 pages, 11 figures, 19 tables, IEEE Communications Surveys & Tutorials, peer-reviewed academic journa

A Comprehensive Review of Digital Twin -- Part 1: Modeling and Twinning Enabling Technologies

As an emerging technology in the era of Industry 4.0, digital twin is gaining unprecedented attention because of its promise to further optimize process design, quality control, health monitoring, decision and policy making, and more, by comprehensively modeling the physical world as a group of interconnected digital models. In a two-part series of papers, we examine the fundamental role of different modeling techniques, twinning enabling technologies, and uncertainty quantification and optimization methods commonly used in digital twins. This first paper presents a thorough literature review of digital twin trends across many disciplines currently pursuing this area of research. Then, digital twin modeling and twinning enabling technologies are further analyzed by classifying them into two main categories: physical-to-virtual, and virtual-to-physical, based on the direction in which data flows. Finally, this paper provides perspectives on the trajectory of digital twin technology over the next decade, and introduces a few emerging areas of research which will likely be of great use in future digital twin research. In part two of this review, the role of uncertainty quantification and optimization are discussed, a battery digital twin is demonstrated, and more perspectives on the future of digital twin are shared

Security and Interpretability in Automotive Systems

Controller area network (CAN) is the most commonly found bus protocol in automotive systems. The two-wire bus protocol helps accomplish sophisticated vehicle services in real-time through complex interactions between hardware components. However, the lack of any sender authentication mechanism in place makes CAN susceptible to security vulnerabilities and threats. To address the insecure nature of the system, this thesis demonstrates a sender authentication technique that uses power consumption measurements of the electronic control units (ECUs) and a classification model to determine the transmitting states of the ECUs. The method's evaluation in real-world settings shows that the technique applies in a broad range of operating conditions and achieves good accuracy. A key challenge of machine learning-based security controls is the potential of false positives. A false-positive alert may induce panic in operators, lead to incorrect reactions, and in the long run cause alarm fatigue. For reliable decision-making in such a circumstance, knowing the cause for unusual model behavior is essential. But, the black-box nature of these models makes them uninterpretable. Therefore, another contribution of this thesis explores explanation techniques for inputs of type image and time series that (1) assign weights to individual inputs based on their sensitivity toward the target class, (2) and quantify the variations in the explanation by reconstructing the sensitive regions of the inputs using a generative model. In summary, this thesis presents methods for addressing the security and interpretability in automotive systems, which can also be applied in other settings where safe, transparent, and reliable decision-making is crucial