Learning and diagnosing faults using neural networks

Neural networks have been employed for learning fault behavior from rocket engine simulator parameters and for diagnosing faults on the basis of the learned behavior. Two problems in applying neural networks to learning and diagnosing faults are (1) the complexity of the sensor data to fault mapping to be modeled by the neural network, which implies difficult and lengthy training procedures; and (2) the lack of sufficient training data to adequately represent the very large number of different types of faults which might occur. Methods are derived and tested in an architecture which addresses these two problems. First, the sensor data to fault mapping is decomposed into three simpler mappings which perform sensor data compression, hypothesis generation, and sensor fusion. Efficient training is performed for each mapping separately. Secondly, the neural network which performs sensor fusion is structured to detect new unknown faults for which training examples were not presented during training. These methods were tested on a task of fault diagnosis by employing rocket engine simulator data. Results indicate that the decomposed neural network architecture can be trained efficiently, can identify faults for which it has been trained, and can detect the occurrence of faults for which it has not been trained

Investigation of a Neural Network Approach in Modeling and Diagnostics of an Engine-out NOx Sensor

The objective of this study was to develop a method for fault detection of an engine-out oxides of nitrogen (NOx) sensor. The aim of the developed method was not only to isolate a fault with the NOx sensor, but to also diagnose faults in other engine subsystems that may result in higher engine-out NOx production. The developed fault diagnostics are aimed at providing reliable, accurate determinations of sensor output, in-lieu of physical sensors.;The data for the development of numerical models in this study was derived from in-use emissions data of a 2014 Freightliner equipped with a 2013 Cummins ISX15 engine. Data included engine control unit (ECU) data from a variety of vehicle operation in southern California that included interstate, highway, regional, local, and near dock locations.;For this method of fault detection, a virtual sensor was created using an artificial neural network (ANN) with an input configuration using 12 engine parameters, which provided the most accurate results in this study. These parameters included engine speed, engine torque, fuel rate, intake temperature, boost pressure, exhaust temperature, coolant temperature, oil pressure, the first derivative of engine speed, the first derivative of engine torque, the second derivative of engine speed, and the second derivative of engine torque. The neural network could then be used to predict expected NOx values.;The ANN NOx model was trained on a subset of the data and later validated with another subset of the available ECU data. Two different sets of training data, and seven validation data sets were used for prediction evaluation. The study also included the insertion of fault data and run against the model to test for fault detection with the best performing data set. It was found that the network is able to predict NOx within 1-5% at highway operation, when trained with highway data, enabling the detection of NOx sensor faults as well as faults in engine subsystems that were included in the input parameters for the neural network. Three different types of sensor failures, including a step, ramp, and square function failure, were implemented in the validation data, which caused an increase in error between the actual and predicted NOx production to increase between 15-200%, creating the means of detection

Fault detection, identification and accommodation techniques for unmanned airborne vehicles

Unmanned Airborne Vehicles (UAV) are assuming prominent roles in both the commercial and military aerospace industries. The promise of reduced costs and reduced risk to human life is one of their major attractions, however these low-cost systems are yet to gain acceptance as a safe alternate to manned solutions. The absence of a thinking, observing, reacting and decision making pilot reduces the UAVs capability of managing adverse situations such as faults and failures. This paper presents a review of techniques that can be used to track the system health onboard a UAV. The review is based on a year long literature review aimed at identifying approaches suitable for combating the low reliability and high attrition rates of today’s UAV. This research primarily focuses on real-time, onboard implementations for generating accurate estimations of aircraft health for fault accommodation and mission management (change of mission objectives due to deterioration in aircraft health). The major task of such systems is the process of detection, identification and accommodation of faults and failures (FDIA). A number of approaches exist, of which model-based techniques show particular promise. Model-based approaches use analytical redundancy to generate residuals for the aircraft parameters that can be used to indicate the occurrence of a fault or failure. Actions such as switching between redundant components or modifying control laws can then be taken to accommodate the fault. The paper further describes recent work in evaluating neural-network approaches to sensor failure detection and identification (SFDI). The results of simulations with a variety of sensor failures, based on a Matlab non-linear aircraft model are presented and discussed. Suggestions for improvements are made based on the limitations of this neural network approach with the aim of including a broader range of failures, while still maintaining an accurate model in the presence of these failures

Zero-Shot Motor Health Monitoring by Blind Domain Transition

Continuous long-term monitoring of motor health is crucial for the early detection of abnormalities such as bearing faults (up to 51% of motor failures are attributed to bearing faults). Despite numerous methodologies proposed for bearing fault detection, most of them require normal (healthy) and abnormal (faulty) data for training. Even with the recent deep learning (DL) methodologies trained on the labeled data from the same machine, the classification accuracy significantly deteriorates when one or few conditions are altered. Furthermore, their performance suffers significantly or may entirely fail when they are tested on another machine with entirely different healthy and faulty signal patterns. To address this need, in this pilot study, we propose a zero-shot bearing fault detection method that can detect any fault on a new (target) machine regardless of the working conditions, sensor parameters, or fault characteristics. To accomplish this objective, a 1D Operational Generative Adversarial Network (Op-GAN) first characterizes the transition between normal and fault vibration signals of (a) source machine(s) under various conditions, sensor parameters, and fault types. Then for a target machine, the potential faulty signals can be generated, and over its actual healthy and synthesized faulty signals, a compact, and lightweight 1D Self-ONN fault detector can then be trained to detect the real faulty condition in real time whenever it occurs. To validate the proposed approach, a new benchmark dataset is created using two different motors working under different conditions and sensor locations. Experimental results demonstrate that this novel approach can accurately detect any bearing fault achieving an average recall rate of around 89% and 95% on two target machines regardless of its type, severity, and location.Comment: 13 pages, 9 figures, Journa

Consistency Index-Based Sensor Fault Detection System for Nuclear Power Plant Emergency Situations Using an LSTM Network

A nuclear power plant (NPP) consists of an enormous number of components with complex interconnections. Various techniques to detect sensor errors have been developed to monitor the state of the sensors during normal NPP operation, but not for emergency situations. In an emergency situation with a reactor trip, all the plant parameters undergo drastic changes following the sudden decrease in core reactivity. In this paper, a machine learning model adopting a consistency index is suggested for sensor error detection during NPP emergency situations. The proposed consistency index refers to the soundness of the sensors based on their measurement accuracy. The application of consistency index labeling makes it possible to detect sensor error immediately and specify the particular sensor where the error occurred. From a compact nuclear simulator, selected plant parameters were extracted during typical emergency situations, and artificial sensor errors were injected into the raw data. The trained system successfully generated output that gave both sensor error states and error-free states

An Adaptive Fault-Tolerant Communication Scheme for Body Sensor Networks

A high degree of reliability for critical data transmission is required in body sensor networks (BSNs). However, BSNs are usually vulnerable to channel impairments due to body fading effect and RF interference, which may potentially cause data transmission to be unreliable. In this paper, an adaptive and flexible fault-tolerant communication scheme for BSNs, namely AFTCS, is proposed. AFTCS adopts a channel bandwidth reservation strategy to provide reliable data transmission when channel impairments occur. In order to fulfill the reliability requirements of critical sensors, fault-tolerant priority and queue are employed to adaptively adjust the channel bandwidth allocation. Simulation results show that AFTCS can alleviate the effect of channel impairments, while yielding lower packet loss rate and latency for critical sensors at runtime.Comment: 10 figures, 19 page