Advanced Diagnostic and Prognostic Testbed (ADAPT) Testability Analysis Report

As system designs become more complex, determining the best locations to add sensors and test points for the purpose of testing and monitoring these designs becomes more difficult. Not only must the designer take into consideration all real and potential faults of the system, he or she must also find efficient ways of detecting and isolating those faults. Because sensors and cabling take up valuable space and weight on a system, and given constraints on bandwidth and power, it is even more difficult to add sensors into these complex designs after the design has been completed. As a result, a number of software tools have been developed to assist the system designer in proper placement of these sensors during the system design phase of a project. One of the key functions provided by many of these software programs is a testability analysis of the system essentially an evaluation of how observable the system behavior is using available tests. During the design phase, testability metrics can help guide the designer in improving the inherent testability of the design. This may include adding, removing, or modifying tests; breaking up feedback loops, or changing the system to reduce fault propagation. Given a set of test requirements, the analysis can also help to verify that the system will meet those requirements. Of course, a testability analysis requires that a software model of the physical system is available. For the analysis to be most effective in guiding system design, this model should ideally be constructed in parallel with these efforts. The purpose of this paper is to present the final testability results of the Advanced Diagnostic and Prognostic Testbed (ADAPT) after the system model was completed. The tool chosen to build the model and to perform the testability analysis with is the Testability Engineering and Maintenance System Designer (TEAMS-Designer). The TEAMS toolset is intended to be a solution to span all phases of the system, from design and development through health management and maintenance. TEAMS-Designer is the model-building and testability analysis software in that suite

Testability Analysis and Improvements of Register-Transfer Level Digital Circuits

The paper presents novel testability analysis method applicable to register-transfer level digital circuits. It is shown if each module stored in a design library is equipped both with information related to design and information related to testing, then more accurate testability results can be achieved. A mathematical model based on virtual port conception is utilized to describe the information and proposed testability analysis method. In order to be effective, the method is based on the idea of searching two special digraphs developed for the purpose. Experimental results gained by the method are presented and compared with results of existing methods

Methods and Systems for Fault Diagnosis in Nuclear Power Plants

This research mainly deals with fault diagnosis in nuclear power plants (NPP), based on a framework that integrates contributions from fault scope identification, optimal sensor placement, sensor validation, equipment condition monitoring, and diagnostic reasoning based on pattern analysis. The research has a particular focus on applications where data collected from the existing SCADA (supervisory, control, and data acquisition) system is not sufficient for the fault diagnosis system. Specifically, the following methods and systems are developed. A sensor placement model is developed to guide optimal placement of sensors in NPPs. The model includes 1) a method to extract a quantitative fault-sensor incidence matrix for a system; 2) a fault diagnosability criterion based on the degree of singularities of the incidence matrix; and 3) procedures to place additional sensors to meet the diagnosability criterion. Usefulness of the proposed method is demonstrated on a nuclear power plant process control test facility (NPCTF). Experimental results show that three pairs of undiagnosable faults can be effectively distinguished with three additional sensors selected by the proposed model. A wireless sensor network (WSN) is designed and a prototype is implemented on the NPCTF. WSN is an effective tool to collect data for fault diagnosis, especially for systems where additional measurements are needed. The WSN has distributed data processing and information fusion for fault diagnosis. Experimental results on the NPCTF show that the WSN system can be used to diagnose all six fault scenarios considered for the system. A fault diagnosis method based on semi-supervised pattern classification is developed which requires significantly fewer training data than is typically required in existing fault diagnosis models. It is a promising tool for applications in NPPs, where it is usually difficult to obtain training data under fault conditions for a conventional fault diagnosis model. The proposed method has successfully diagnosed nine types of faults physically simulated on the NPCTF. For equipment condition monitoring, a modified S-transform (MST) algorithm is developed by using shaping functions, particularly sigmoid functions, to modify the window width of the existing standard S-transform. The MST can achieve superior time-frequency resolution for applications that involves non-stationary multi-modal signals, where classical methods may fail. Effectiveness of the proposed algorithm is demonstrated using a vibration test system as well as applications to detect a collapsed pipe support in the NPCTF. The experimental results show that by observing changes in time-frequency characteristics of vibration signals, one can effectively detect faults occurred in components of an industrial system. To ensure that a fault diagnosis system does not suffer from erroneous data, a fault detection and isolation (FDI) method based on kernel principal component analysis (KPCA) is extended for sensor validations, where sensor faults are detected and isolated from the reconstruction errors of a KPCA model. The method is validated using measurement data from a physical NPP. The NPCTF is designed and constructed in this research for experimental validations of fault diagnosis methods and systems. Faults can be physically simulated on the NPCTF. In addition, the NPCTF is designed to support systems based on different instrumentation and control technologies such as WSN and distributed control systems. The NPCTF has been successfully utilized to validate the algorithms and WSN system developed in this research. In a real world application, it is seldom the case that one single fault diagnostic scheme can meet all the requirements of a fault diagnostic system in a nuclear power. In fact, the values and performance of the diagnosis system can potentially be enhanced if some of the methods developed in this thesis can be integrated into a suite of diagnostic tools. In such an integrated system, WSN nodes can be used to collect additional data deemed necessary by sensor placement models. These data can be integrated with those from existing SCADA systems for more comprehensive fault diagnosis. An online performance monitoring system monitors the conditions of the equipment and provides key information for the tasks of condition-based maintenance. When a fault is detected, the measured data are subsequently acquired and analyzed by pattern classification models to identify the nature of the fault. By analyzing the symptoms of the fault, root causes of the fault can eventually be identified

Efficient Detection on Stochastic Faults in PLC Based Automated Assembly Systems With Novel Sensor Deployment and Diagnoser Design

In this dissertation, we proposed solutions on novel sensor deployment and diagnoser design to efficiently detect stochastic faults in PLC based automated systems First, a fuzzy quantitative graph based sensor deployment was called upon to model cause-effect relationship between faults and sensors. Analytic hierarchy process (AHP) was used to aggregate the heterogeneous properties between sensors and faults into single edge values in fuzzy graph, thus quantitatively determining the fault detectability. An appropriate multiple objective model was set up to minimize fault unobservability and cost while achieving required detectability performance. Lexicographical mixed integer linear programming and greedy search were respectively used to optimize the model, thus assigning the sensors to faults. Second, a diagnoser based on real time fuzzy Petri net (RTFPN) was proposed to detect faults in discrete manufacturing systems. It used the real time PN to model the manufacturing plant while using fuzzy PN to isolate the faults. It has the capability of handling uncertainties and including industry knowledge to diagnose faults. The proposed approach was implemented using Visual Basic, and tested as well as validated on a dual robot arm. Finally, the proposed sensor deployment approach and diagnoser were comprehensively evaluated based on design of experiment techniques. Two-stage statistical analysis including analysis of variance (ANOVA) and least significance difference (LSD) were conducted to evaluate the diagnosis performance including positive detection rate, false alarm, accuracy and detect delay. It illustrated the proposed approaches have better performance on those evaluation metrics. The major contributions of this research include the following aspects: (1) a novel fuzzy quantitative graph based sensor deployment approach handling sensor heterogeneity, and optimizing multiple objectives based on lexicographical integer linear programming and greedy algorithm, respectively. A case study on a five tank system showed that system detectability was improved from the approach of signed directed graph's 0.62 to the proposed approach's 0.70. The other case study on a dual robot arm also show improvement on system's detectability improved from the approach of signed directed graph's 0.61 to the proposed approach's 0.65. (2) A novel real time fuzzy Petri net diagnoser was used to remedy nonsynchronization and integrate useful but incomplete knowledge for diagnosis purpose. The third case study on a dual robot arm shows that the diagnoser can achieve a high detection accuracy of 93% and maximum detection delay of eight steps. (3) The comprehensive evaluation approach can be referenced by other diagnosis systems' design, optimization and evaluation

Optimal coordinate sensor placements for estimating mean and variance components of variation sources

In-process Optical Coordinate Measuring Machine (OCMM) offers the potential of diagnosing in a timely manner variation sources that are responsible for product quality defects. Such a sensor system can help manufacturers improve product quality and reduce process downtime. Effective use of sensory data in diagnosing variation sources depends on the optimal design of a sensor system, which is often known as the problem of sensor placements. This thesis addresses coordinate sensor placement in diagnosing dimensional variation sources in assembly processes. Sensitivity indices of detecting process mean and variance components are defined as the design criteria and are derived in terms of process layout and sensor deployment information. Exchange algorithms, originally developed in the research of optimal experiment deign, are employed and revised to maximize the detection sensitivity. A sort-and-cut procedure is used, which remarkably improve the algorithm efficiency of the current exchange routine. The resulting optimal sensor layouts and its implications are illustrated in the specific context of a panel assembly process

A general algorithm for pattern diagnosability of distributed discrete event systems

International audienceDiagnosability is an important system property that determines at design stage how accurate any diagnostic reasoning can be on a partially observed system. A fault in a system is diagnosable iff its occurrence can always be deduced from enough observations. The centralized diagnosability approaches lead to state explosion since they assume the existence of a monolithic model of the system. This is why very recently the distributed approaches for diagnosability began to be investigated, relying on local objects. On the other hand, diagnosis objectives are generalized from fault event to fault pattern that can represent multiple faults, repeating fault, sequences of significant events, etc. For pattern case, most existing approaches are centralized. In this paper, we propose a new distributed framework for pattern diagnosability. We first show how to recognize patterns by incrementally constructing local pattern recognizers. Then we propose a structure called regional pattern verifier constructed from the subsystem where the pattern is completely recognized before showing how to abstract the necessary and sufficient diagnosability information to further save the search space. Then the global consistency checking is based on another local structure called abstracted local twin checker to analyze pattern diagnosability. The correctness of our distributed algorithm is theoretically proved and its efficiency experimentally demonstrated by the results of the implementation

Property Enforcement for Partially-Observed Discrete-Event Systems

Engineering systems that involve physical elements, such as automobiles, aircraft, or electric power pants, that are controlled by a computational infrastructure that consists of several computers that communicate through a communication network, are called Cyber-Physical Systems. Ever-increasing demands for safety, security, performance, and certi cation of these critical systems put stringent constraints on their design and necessitate the use of formal model-based approaches to synthesize provably-correct feedback controllers. This dissertation aims to tackle these challenges by developing a novel methodology for synthesis of control and sensing strategies for Discrete Event Systems (DES), an important class of cyber-physical systems. First, we develop a uniform approach for synthesizing property enforcing supervisors for a wide class of properties called information-state-based (IS-based) properties. We then consider the enforcement of non-blockingness in addition to IS-based properties. We develop a nite structure called the All Enforcement Structure (AES) that embeds all valid supervisors. Furthermore, we propose novel and general approaches to solve the sensor activation problem for partially-observed DES. We extend our results for the sensor activation problem from the centralized case to the decentralized case. The methodology in the dissertation has the following novel features: (i) it explicitly considers and handles imperfect state information, due to sensor noise, and limited controllability, due to unexpected environmental disturbances; (ii) it is a uniform information-state-based approach that can be applied to a variety of user-speci ed requirements; (iii) it is a formal model-based approach, which results in provably correct solutions; and (iv) the methodology and associated theoretical foundations developed are generic and applicable to many types of networked cyber-physical systems with safety-critical requirements, in particular networked systems such as aircraft electric power systems and intelligent transportation systems.PHDElectrical Engineering: SystemsUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttps://deepblue.lib.umich.edu/bitstream/2027.42/137097/1/xiangyin_1.pd