Condition Monitoring and Fault Diagnosis of a Marine Diesel Engine with Machine Learning Techniques

A marine engine room is a complex system in which many different subsystems are interacting with each other. At the center of this system is the main diesel engine which produces the propulsion force. Many other components such as compressed air, cooling, heating, lubricating oil, fuel, and pumping systems act as auxiliary machines to the main engine. Automation of many functions in the engine room is starting to play an important role in new generation ships to provide better control using sensors monitoring the engine and its environment. Sensors exist in the current generation ships, but engineers evaluate the sensor data for the presence of any problems. Maintenance actions are taken based on these manual analyses or regular maintenance is carried out at times determined by manufacturers, whether such actions are needed or not. With machine learning, it is possible to develop an algorithm using past evaluations made by engineers. Recent studies show that highly accurate results can be obtained using machine learning methods when there is sufficient data. In this study, we develop new learning-based algorithms and evaluate them on data obtained from a realistic ship engine room simulator. Data for a predetermined set of parameters of a high-power diesel engine were collected and analyzed for their role in a set of fault situations. These fault conditions and the associated sensor data are used to train a set of classifiers achieving fault detection up to 99% accuracy. These are promising results in preventing future damage to the engine or its supporting components by predicting failures before they occur

Multidimensional prognostics for rotating machinery: A review

open access articleDetermining prognosis for rotating machinery could potentially reduce maintenance costs and improve safety and avail- ability. Complex rotating machines are usually equipped with multiple sensors, which enable the development of multidi- mensional prognostic models. By considering the possible synergy among different sensor signals, multivariate models may provide more accurate prognosis than those using single-source information. Consequently, numerous research papers focusing on the theoretical considerations and practical implementations of multivariate prognostic models have been published in the last decade. However, only a limited number of review papers have been written on the subject. This article focuses on multidimensional prognostic models that have been applied to predict the failures of rotating machinery with multiple sensors. The theory and basic functioning of these techniques, their relative merits and draw- backs and how these models have been used to predict the remnant life of a machine are discussed in detail. Furthermore, this article summarizes the rotating machines to which these models have been applied and discusses future research challenges. The authors also provide seven evaluation criteria that can be used to compare the reviewed techniques. By reviewing the models reported in the literature, this article provides a guide for researchers considering prognosis options for multi-sensor rotating equipment

A Literature Review of Fault Diagnosis Based on Ensemble Learning

The accuracy of fault diagnosis is an important indicator to ensure the reliability of key equipment systems. Ensemble learning integrates different weak learning methods to obtain stronger learning and has achieved remarkable results in the field of fault diagnosis. This paper reviews the recent research on ensemble learning from both technical and field application perspectives. The paper summarizes 87 journals in recent web of science and other academic resources, with a total of 209 papers. It summarizes 78 different ensemble learning based fault diagnosis methods, involving 18 public datasets and more than 20 different equipment systems. In detail, the paper summarizes the accuracy rates, fault classification types, fault datasets, used data signals, learners (traditional machine learning or deep learning-based learners), ensemble learning methods (bagging, boosting, stacking and other ensemble models) of these fault diagnosis models. The paper uses accuracy of fault diagnosis as the main evaluation metrics supplemented by generalization and imbalanced data processing ability to evaluate the performance of those ensemble learning methods. The discussion and evaluation of these methods lead to valuable research references in identifying and developing appropriate intelligent fault diagnosis models for various equipment. This paper also discusses and explores the technical challenges, lessons learned from the review and future development directions in the field of ensemble learning based fault diagnosis and intelligent maintenance

Multidimensional prognostics for rotating machinery: A review

Determining prognosis for rotating machinery could potentially reduce maintenance costs and improve safety and availability. Complex rotating machines are usually equipped with multiple sensors, which enable the development of multidimensional prognostic models. By considering the possible synergy among different sensor signals, multivariate models may provide more accurate prognosis than those using single-source information. Consequently, numerous research papers focusing on the theoretical considerations and practical implementations of multivariate prognostic models have been published in the last decade. However, only a limited number of review papers have been written on the subject. This article focuses on multidimensional prognostic models that have been applied to predict the failures of rotating machinery with multiple sensors. The theory and basic functioning of these techniques, their relative merits and drawbacks and how these models have been used to predict the remnant life of a machine are discussed in detail. Furthermore, this article summarizes the rotating machines to which these models have been applied and discusses future research challenges. The authors also provide seven evaluation criteria that can be used to compare the reviewed techniques. By reviewing the models reported in the literature, this article provides a guide for researchers considering prognosis options for multi-sensor rotating equipment

Systems Engineering: Availability and Reliability

Current trends in Industry 4.0 are largely related to issues of reliability and availability. As a result of these trends and the complexity of engineering systems, research and development in this area needs to focus on new solutions in the integration of intelligent machines or systems, with an emphasis on changes in production processes aimed at increasing production efficiency or equipment reliability. The emergence of innovative technologies and new business models based on innovation, cooperation networks, and the enhancement of endogenous resources is assumed to be a strong contribution to the development of competitive economies all around the world. Innovation and engineering, focused on sustainability, reliability, and availability of resources, have a key role in this context. The scope of this Special Issue is closely associated to that of the ICIE’2020 conference. This conference and journal’s Special Issue is to present current innovations and engineering achievements of top world scientists and industrial practitioners in the thematic areas related to reliability and risk assessment, innovations in maintenance strategies, production process scheduling, management and maintenance or systems analysis, simulation, design and modelling

Development of Machine Learning based approach to predict fuel consumption and maintenance cost of Heavy-Duty Vehicles using diesel and alternative fuels

One of the major contributors of human-made greenhouse gases (GHG) namely carbon dioxide (CO2), methane (CH4), and nitrous oxide (NOX) in the transportation sector and heavy-duty vehicles (HDV) contributing to about 27% of the overall fraction. In addition to the rapid increase in global temperature, airborne pollutants from diesel vehicles also present a risk to human health. Even a small improvement that could potentially drive energy savings to the century-old mature diesel technology could yield a significant impact on minimizing greenhouse gas emissions. With the increasing focus on reducing emissions and operating costs, there is a need for efficient and effective methods to predict fuel consumption, maintenance costs, and total cost of ownership for heavy-duty vehicles. Every improvement so achieved in this direction is a direct contributor to driving the reduction in the total cost of ownership for a fleet owner, thereby bringing economic prosperity and reducing oil imports for the economy. Motivated by these crucial goals, the present research considers integrating data-driven techniques using machine learning algorithms on the historical data collected from medium- and heavy-duty vehicles. The primary motivation for this research is to address the challenges faced by the medium- and heavy-duty transportation industry in reducing emissions and operating costs. The development of a machine learning-based approach can provide a more accurate and reliable prediction of fuel consumption and maintenance costs for medium- and heavy-duty vehicles. This, in turn, can help fleet owners and operators to make informed decisions related to fuel type, route planning, and vehicle maintenance, leading to reduced emissions and lower operating costs. Artificial Intelligence (AI) in the automotive industry has witnessed massive growth in the last few years. Heavy-duty transportation research and commercial fleets are adopting machine learning (ML) techniques for applications such as autonomous driving, fuel economy/emissions, predictive maintenance, etc. However, to perform well, modern AI methods require a large amount of high-quality, diverse, and well-balanced data, something which is still not widely available in the automotive industry, especially in the division of medium- and heavy-duty trucks. The research methodology involves the collection of data at the West Virginia University (WVU) Center for Alternative Fuels, Engines, and Emissions (CAFEE) lab in collaboration with fleet management companies operating medium- and heavy-duty vehicles on diesel and alternative fuels, including compressed natural gas, liquefied propane gas, hydrogen fuel cells, and electric vehicles. The data collected is used to develop machine learning models that can accurately predict fuel consumption and maintenance costs based on various parameters such as vehicle weight, speed, route, fuel type, and engine type. The expected outcomes of this research include 1) the development of a neural network model 3 that can accurately predict the fuel consumed by a vehicle per trip given the parameters such as vehicle speed, engine speed, and engine load, and 2) the development of machine learning models for estimating the average cost-per-mile based on the historical maintenance data of goods movement trucks, delivery trucks, school buses, transit buses, refuse trucks, and vocational trucks using fuels such as diesel, natural gas, and propane. Due to large variations in maintenance data for vehicles performing various activities and using different fuel types, the regular machine learning or ensemble models do not generalize well. Hence, a mixed-effect random forest (MERF) is developed to capture the fixed and random effects that occur due to varying duty-cycle of vocational heavy-duty trucks that perform different tasks. The developed model helps in predicting the average maintenance cost given the vocation, fuel type, and region of operation, making it easy for fleet companies to make procurement decisions based on their requirement and total cost of ownership. Both the models can provide insights into the impact of various parameters and route planning on the total cost of ownership affected by the fuel cost and the maintenance and repairs cost. In conclusion, the development of a machine learning-based approach can provide a reliable and efficient solution to predict fuel consumption and maintenance costs impacting the total cost of ownership for heavy-duty vehicles. This, in turn, can help the transportation industry reduce emissions and operating costs, contributing to a more sustainable and efficient transportation system. These models can be optimized with more training data and deployed in a real-time environment such as cloud service or an onboard vehicle system as per the requirement of companies

Advanced Sensors for Real-Time Monitoring Applications

It is impossible to imagine the modern world without sensors, or without real-time information about almost everything—from local temperature to material composition and health parameters. We sense, measure, and process data and act accordingly all the time. In fact, real-time monitoring and information is key to a successful business, an assistant in life-saving decisions that healthcare professionals make, and a tool in research that could revolutionize the future. To ensure that sensors address the rapidly developing needs of various areas of our lives and activities, scientists, researchers, manufacturers, and end-users have established an efficient dialogue so that the newest technological achievements in all aspects of real-time sensing can be implemented for the benefit of the wider community. This book documents some of the results of such a dialogue and reports on advances in sensors and sensor systems for existing and emerging real-time monitoring applications

Deep Learning-Based Machinery Fault Diagnostics

This book offers a compilation for experts, scholars, and researchers to present the most recent advancements, from theoretical methods to the applications of sophisticated fault diagnosis techniques. The deep learning methods for analyzing and testing complex mechanical systems are of particular interest. Special attention is given to the representation and analysis of system information, operating condition monitoring, the establishment of technical standards, and scientific support of machinery fault diagnosis