Acoustic Condition Monitoring & Fault Diagnostics for Industrial Systems

Condition monitoring and fault diagnostics for industrial systems is required for cost reduction, maintenance scheduling, and reducing system failures. Catastrophic failure usually causes significant damage and may cause injury or fatality, making early and accurate fault diagnostics of paramount importance. Existing diagnostics can be improved by augmenting or replacing with acoustic measurements, which have proven advantages over more traditional vibration measurements including, earlier detection of emerging faults, increased diagnostic accuracy, remote sensors and easier setup and operation. However, industry adoption of acoustics remains in relative infancy due to vested confidence and reliance on existing measurement and, perceived difficulties with noise contamination and diagnostic accuracy. Researched acoustic monitoring examples typically employ specialist surface-mount transducers, signal amplification, and complex feature extraction and machine learning algorithms, focusing on noise rejection and fault classification. Usually, techniques are fine-tuned to maximise diagnostic performance for the given problem. The majority investigate mechanical fault modes, particularly Roller Element Bearings (REBs), owing to the mechanical impacts producing detectable acoustic waves. The first contribution of this project is a suitability study into the use of low-cost consumer-grade acoustic sensors for fault diagnostics of six different REB health conditions, comparing against vibration measurements. Experimental results demonstrate superior acoustic performance throughout but particularly at lower rotational speed and axial load. Additionally, inaccuracies caused by dynamic operational parameters (speed in this case), are minimised by novel multi-Support Vector Machine training. The project then expands on existing work to encompass diagnostics for a previously unreported electrical fault mode present on a Brush-Less Direct Current motor drive system. Commonly studied electrical faults, such as a broken rotor bar or squirrel cage, result from mechanical component damage artificially seeded and not spontaneous. Here, electrical fault modes are differentiated as faults caused by issues with the power supply, control system or software (not requiring mechanical damage or triggering intervention). An example studied here is a transient current instability, generated by non-linear interaction of the motor electrical parameters, parasitic components and digital controller realisation. Experimental trials successfully demonstrate real-time feature extraction and further validate consumer-grade sensors for industrial system diagnostics. Moreover, this marks the first known diagnosis of an electrically-seeded fault mode as defined in this work. Finally, approaching an industry-ready diagnostic system, the newly released PYNQ-Z2 Field Programmable Gate Array is used to implement the first known instance of multiple feature extraction algorithms that operate concurrently in continuous real-time. A proposed deep-learning algorithm can analyse the features to determine the optimum feature extraction combination for ongoing continuous monitoring. The proposed black-box, all-in-one solution, is capable of accurate unsupervised diagnostics on almost any application, maintaining excellent diagnostic performance. This marks a major leap forward from fine-tuned feature extraction performed offline for artificially seeded mechanical defects to multiple real-time feature extraction demonstrated on a spontaneous electrical fault mode with a versatile and adaptable system that is low-cost, readily available, with simple setup and operation. The presented concept represents an industry-ready all-in-one acoustic diagnostic solution, that is hoped to increase adoption of acoustic methods, greatly improving diagnostics and minimising catastrophic failures

Latitude, longitude, and beyond:mining mobile objects' behavior

Rapid advancements in Micro-Electro-Mechanical Systems (MEMS), and wireless communications, have resulted in a surge in data generation. Mobility data is one of the various forms of data, which are ubiquitously collected by different location sensing devices. Extensive knowledge about the behavior of humans and wildlife is buried in raw mobility data. This knowledge can be used for realizing numerous viable applications ranging from wildlife movement analysis, to various location-based recommendation systems, urban planning, and disaster relief. With respect to what mentioned above, in this thesis, we mainly focus on providing data analytics for understanding the behavior and interaction of mobile entities (humans and animals). To this end, the main research question to be addressed is: How can behaviors and interactions of mobile entities be determined from mobility data acquired by (mobile) wireless sensor nodes in an accurate and efficient manner? To answer the above-mentioned question, both application requirements and technological constraints are considered in this thesis. On the one hand, applications requirements call for accurate data analytics to uncover hidden information about individual behavior and social interaction of mobile entities, and to deal with the uncertainties in mobility data. Technological constraints, on the other hand, require these data analytics to be efficient in terms of their energy consumption and to have low memory footprint, and processing complexity

Algorithms for Energy Efficiency in Wireless Sensor Networks

The recent advances in microsensor and semiconductor technology have opened a new field within computer science: the networking of small-sized sensors which are capable of sensing, processing, and communicating. Such wireless sensor networks offer new applications in the areas of habitat and environment monitoring, disaster control and operation, military and intelligence control, object tracking, video surveillance, traffic control, as well as in health care and home automation. It is likely that the deployed sensors will be battery-powered, which will limit the energy capacity significantly. Thus, energy efficiency becomes one of the main challenges that need to be taken into account, and the design of energy-efficient algorithms is a major contribution of this thesis. As the wireless communication in the network is one of the main energy consumers, we first consider in detail the characteristics of wireless communication. By using the embedded sensor board (ESB) platform recently developed by the Free University of Berlin, we analyze the means of forward error correction and propose an appropriate resync mechanism, which improves the communication between two ESB nodes substantially. Afterwards, we focus on the forwarding of data packets through the network. We present the algorithms energy-efficient forwarding (EEF), lifetime-efficient forwarding (LEF), and energy-efficient aggregation forwarding (EEAF). While EEF is designed to maximize the number of data bytes delivered per energy unit, LEF additionally takes into account the residual energy of forwarding nodes. In so doing, LEF further prolongs the lifetime of the network. Energy savings due to data aggregation and in-network processing are exploited by EEAF. Besides single-link forwarding, in which data packets are sent to only one forwarding node, we also study the impact of multi-link forwarding, which exploits the broadcast characteristics of the wireless medium by sending packets to several (potential) forwarding nodes. By actively selecting a forwarder among all nodes that received a packet successfully, retransmissions can often be avoided. In the majority of cases, multi-link forwarding is thus more efficient and able to save energy. In the last part of this thesis, we present a topology and energy control algorithm (TECA) to turn off the nodes' radio transceivers completely in order to avoid idle listening. By means of TECA, a connected backbone of active nodes is established, while all other nodes may sleep and save energy by turning off their radios. All algorithms presented in this thesis have been fully analyzed, simulated, and implemented on the ESB platform. They are suitable for several applications scenarios and can easily be adapted even to other wireless sensor platforms