Prediction of industrial equipment Remaining Useful Life by fuzzy similarity and belief function theory

We develop a novel prognostic method for estimating the Remaining Useful Life (RUL) of industrial equipment and its uncertainty. The novelty of the work is the combined use of a fuzzy similarity method for the RUL prediction and of Belief Function Theory for uncertainty treatment. This latter allows estimating the uncertainty affecting the RUL predictions even in cases characterized by few available data, in which traditional uncertainty estimation methods tend to fail. From the practical point of view, the maintenance planner can define the maximum acceptable failure probability for the equipment of interest and is informed by the proposed prognostic method of the time at which this probability is exceeded, allowing the adoption of a predictive maintenance approach which takes into account RUL uncertainty. The method is applied to simulated data of creep growth in ferritic steel and to real data of filter clogging taken from a Boiling Water Reactor (BWR) condenser. The obtained results show the effectiveness of the proposed method for uncertainty treatment and its superiority to the Kernel Density Estimation (KDE) and the Mean-Variance Estimation (MVE) methods in terms of reliability and precision of the RUL prediction intervals

Remaining useful life estimation in heterogeneous fleets working under variable operating conditions

The availability of condition monitoring data for large fleets of similar equipment motivates the development of data-driven prognostic approaches that capitalize on the information contained in such data to estimate equipment Remaining Useful Life (RUL). A main difficulty is that the fleet of equipment typically experiences different operating conditions, which influence both the condition monitoring data and the degradation processes that physically determine the RUL. We propose an approach for RUL estimation from heterogeneous fleet data based on three phases: firstly, the degradation levels (states) of an homogeneous discrete-time finite-state semi-markov model are identified by resorting to an unsupervised ensemble clustering approach. Then, the parameters of the discrete Weibull distributions describing the transitions among the states and their uncertainties are inferred by resorting to the Maximum Likelihood Estimation (MLE) method and to the Fisher Information Matrix (FIM), respectively. Finally, the inferred degradation model is used to estimate the RUL of fleet equipment by direct Monte Carlo (MC) simulation. The proposed approach is applied to two case studies regarding heterogeneous fleets of aluminium electrolytic capacitors and turbofan engines. Results show the effectiveness of the proposed approach in predicting the RUL and its superiority compared to a fuzzy similarity-based approach of literature

A switching ensemble approach for remaining useful life estimation of electrolytic capacitors

open4In this work, we consider the problem of predicting an equipment Remaining Useful Life (RUL), based on data from a fleet of similar components working under different operating conditions (Al-Dahidi et al. 2015).Al-Dahidi, S.; Di Maio, F.; Baraldi, P.; Zio, E.AL-DAHIDI, SAMEER MAHMOUD AHMED; DI MAIO, Francesco; Baraldi, Piero; Zio, Enric

Review of Health Prognostics and Condition Monitoring of Electronic Components

To meet the specifications of low cost, highly reliable electronic devices, fault diagnosis techniques play an essential role. It is vital to find flaws at an early stage in design, components, material, or manufacturing during the initial phase. This review paper attempts to summarize past development and recent advances in the areas about green manufacturing, maintenance, remaining useful life (RUL) prediction, and like. The current state of the art in reliability research for electronic components, mainly includes failure mechanisms, condition monitoring, and residual lifetime evaluation is explored. A critical analysis of reliability studies to identify their relative merits and usefulness of the outcome of these studies' vis-a-vis green manufacturing is presented. The wide array of statistical, empirical, and intelligent tools and techniques used in the literature are then identified and mapped. Finally, the findings are summarized, and the central research gap is highlighted

A belief function theory based approach to combining different representation of uncertainty in prognostics

International audienceIn this work, we consider two prognostic approaches for the prediction of the remaining useful life (RUL) of degrading equipment. The first approach is based on Gaussian Process Regression (GPR) and provides the probability distribution of the equipment RUL; the second approach adopts a Similarity-Based Regression (SBR) method for the RUL prediction and belief function theory for modeling the uncertainty on the prediction. The performance of the two approaches is comparable and we propose a method for combining their outcomes in an ensemble. The least commitment principle is adopted to transform the RUL probability density function supplied by the GPR method into a belief density function. Then, the Dempster's rule is used to aggregate the belief assignments provided by the GPR and the SBR approaches. The ensemble method is applied to the problem of predicting the RUL of filters used to clean the sea water entering the condenser of the boiling water reactor (BWR) in a Swedish nuclear power plant. The results by the ensemble method are shown to be more satisfactory than that provided by the individual GPR and SBR approaches from the point of view of the representation of the uncertainty in the RUL prediction

Instantaneous failure mode remaining useful life estimation using non-uniformly sampled measurements from a reciprocating compressor valve failure

One of the major targets in industry is minimisation of downtime and cost, and maximisation of availability and safety, with maintenance considered a key aspect in achieving this objective. The concept of Condition Based Maintenance and Prognostics and Health Management (CBM/PHM) , which is founded on the principles of diagnostics, and prognostics, is a step towards this direction as it offers a proactive means for scheduling maintenance. Reciprocating compressors are vital components in oil and gas industry, though their maintenance cost is known to be relatively high. Compressor valves are the weakest part, being the most frequent failing component, accounting for almost half maintenance cost. To date, there has been limited information on estimating Remaining Useful Life (RUL) of reciprocating compressor in the open literature. This paper compares the prognostic performance of several methods (multiple linear regression, polynomial regression, Self-Organising Map (SOM), K-Nearest Neighbours Regression (KNNR)), in relation to their accuracy and precision, using actual valve failure data captured from an operating industrial compressor. The SOM technique is employed for the first time as a standalone tool for RUL estimation. Furthermore, two variations on estimating RUL based on SOM and KNNR respectively are proposed. Finally, an ensemble method by combining the output of all aforementioned algorithms is proposed and tested. Principal components analysis and statistical process control were implemented to create T^2 and Q metrics, which were proposed to be used as health indicators reflecting degradation processes and were employed for direct RUL estimation for the first time. It was shown that even when RUL is relatively short due to instantaneous nature of failure mode, it is feasible to perform good RUL estimates using the proposed techniques

Evolving Clustering Algorithms And Their Application For Condition Monitoring, Diagnostics, & Prognostics

Applications of Condition-Based Maintenance (CBM) technology requires effective yet generic data driven methods capable of carrying out diagnostics and prognostics tasks without detailed domain knowledge and human intervention. Improved system availability, operational safety, and enhanced logistics and supply chain performance could be achieved, with the widespread deployment of CBM, at a lower cost level. This dissertation focuses on the development of a Mutual Information based Recursive Gustafson-Kessel-Like (MIRGKL) clustering algorithm which operates recursively to identify underlying model structure and parameters from stream type data. Inspired by the Evolving Gustafson-Kessel-like Clustering (eGKL) algorithm, we applied the notion of mutual information to the well-known Mahalanobis distance as the governing similarity measure throughout. This is also a special case of the Kullback-Leibler (KL) Divergence where between-cluster shape information (governed by the determinant and trace of the covariance matrix) is omitted and is only applicable in the case of normally distributed data. In the cluster assignment and consolidation process, we proposed the use of the Chi-square statistic with the provision of having different probability thresholds. Due to the symmetry and boundedness property brought in by the mutual information formulation, we have shown with real-world data that the algorithm’s performance becomes less sensitive to the same range of probability thresholds which makes system tuning a simpler task in practice. As a result, improvement demonstrated by the proposed algorithm has implications in improving generic data driven methods for diagnostics, prognostics, generic function approximations and knowledge extractions for stream type of data. The work in this dissertation demonstrates MIRGKL’s effectiveness in clustering and knowledge representation and shows promising results in diagnostics and prognostics applications

Prognostics and Health Management of Industrial Equipment

ISBN13: 9781466620957Prognostics and health management (PHM) is a field of research and application which aims at making use of past, present and future information on the environmental, operational and usage conditions of an equipment in order to detect its degradation, diagnose its faults, predict and proactively manage its failures. The present paper reviews the state of knowledge on the methods for PHM, placing these in context with the different information and data which may be available for performing the task and identifying the current challenges and open issues which must be addressed for achieving reliable deployment in practice. The focus is predominantly on the prognostic part of PHM, which addresses the prediction of equipment failure occurrence and associated residual useful life (RUL)

Novel failure prognostics approach with dynamic thresholds for machine degradation.

International audienceEstimating remaining useful life (RUL) of critical machinery is a challenging task. It is achieved through essential steps of data acquisition, data pre-processing and prognostics modeling. To estimate RUL of a degrading machinery, prognostics modeling phase requires precise knowledge about failure threshold (FT) (or failure definition). Practically, degrading machinery can have different levels (states) of degradation before failure, and prognostics can be quite complicated or even impossible when there is absence of prior knowledge about actual states of degrading machinery or FT. In this paper a novel approach is proposed to improve failure prognostics. In brief, the proposed prognostics model integrates two new algorithms, namely, a Summation Wavelet Extreme Learning Machine (SWELM) and Subtractive-Maximum Entropy Fuzzy Clustering (S-MEFC) to predict degrading behavior, automatically identify the states of degrading machinery, and to dynamically assign FT. Indeed, for practical reasons there is no interest in assuming FT for RUL estimation. The effectiveness of the approach is judged by applying it to real dataset in order to estimate future breakdown of a real machinery