Experimental set-up for investigation of fault diagnosis of a centrifugal pump

Centrifugal pumps are complex machines which can experience different types of fault. Condition monitoring can be used in centrifugal pump fault detection through vibration analysis for mechanical and hydraulic forces. Vibration analysis methods have the potential to be combined with artificial intelligence systems where an automatic diagnostic method can be approached. An automatic fault diagnosis approach could be a good option to minimize human error and to provide a precise machine fault classification. This work aims to introduce an approach to centrifugal pump fault diagnosis based on artificial intelligence and genetic algorithm systems. An overview of the future works, research methodology and proposed experimental setup is presented and discussed. The expected results and outcomes based on the experimental work are illustrated

Integration of a failure monitoring within a hybrid dynamic simulation environment

The complexity and the size of the industrial chemical processes induce the monitoring of a growing number of process variables. Their knowledge is generally based on the measurements of system variables and on the physico-chemical models of the process. Nevertheless this information is imprecise because of process and measurement noise. So the research ways aim at developing new and more powerful techniques for the detection of process fault. In this work, we present a method for the fault detection based on the comparison between the real system and the reference model evolution generated by the extended Kalman filter. The reference model is simulated by the dynamic hybrid simulator, PrODHyS. It is a general object-oriented environment which provides common and reusable components designed for the development and the management of dynamic simulation of industrial systems. The use of this method is illustrated through a didactic example relating to the field of Chemical Process System Engineering

Use of COTS functional analysis software as an IVHM design tool for detection and isolation of UAV fuel system faults

This paper presents a new approach to the development of health management solutions which can be applied to both new and legacy platforms during the conceptual design phase. The approach involves the qualitative functional modelling of a system in order to perform an Integrated Vehicle Health Management (IVHM) design – the placement of sensors and the diagnostic rules to be used in interrogating their output. The qualitative functional analysis was chosen as a route for early assessment of failures in complex systems. Functional models of system components are required for capturing the available system knowledge used during various stages of system and IVHM design. MADe™ (Maintenance Aware Design environment), a COTS software tool developed by PHM Technology, was used for the health management design. A model has been built incorporating the failure diagrams of five failure modes for five different components of a UAV fuel system. Thus an inherent health management solution for the system and the optimised sensor set solution have been defined. The automatically generated sensor set solution also contains a diagnostic rule set, which was validated on the fuel rig for different operation modes taking into account the predicted fault detection/isolation and ambiguity group coefficients. It was concluded that when using functional modelling, the IVHM design and the actual system design cannot be done in isolation. The functional approach requires permanent input from the system designer and reliability engineers in order to construct a functional model that will qualitatively represent the real system. In other words, the physical insight should not be isolated from the failure phenomena and the diagnostic analysis tools should be able to adequately capture the experience bases. This approach has been verified on a laboratory bench top test rig which can simulate a range of possible fuel system faults. The rig is fully instrumented in order to allow benchmarking of various sensing solution for fault detection/isolation that were identified using functional analysis

A combined sensitivity analysis and kriging surrogate modeling for early validation of health indicators

To increase the dependability of complex systems, one solution is to assess their state of health continuously through the monitoring of variables sensitive to potential degradation modes. When computed in an operating environment, these variables, known as health indicators, are subject to many uncertainties. Hence, the stochastic nature of health assessment combined with the lack of data in design stages makes it difficult to evaluate the efficiency of a health indicator before the system enters into service. This paper introduces a method for early validation of health indicators during the design stages of a system development process. This method uses physics-based modeling and uncertainties propagation to create simulated stochastic data. However, because of the large number of parameters defining the model and its computation duration, the necessary runtime for uncertainties propagation is prohibitive. Thus, kriging is used to obtain low computation time estimations of the model outputs. Moreover, sensitivity analysis techniques are performed upstream to determine the hierarchization of the model parameters and to reduce the dimension of the input space. The validation is based on three types of numerical key performance indicators corresponding to the detection, identification and prognostic processes. After having introduced and formalized the framework of uncertain systems modeling and the different performance metrics, the issues of sensitivity analysis and surrogate modeling are addressed. The method is subsequently applied to the validation of a set of health indicators for the monitoring of an aircraft engine's pumping unit

Diagnostics of an Aircraft Engine Pumping Unit Using a Hybrid Approach based-on Surrogate Modeling

This document introduces a hybrid approach for fault detection and identification of an aircraft engine pumping unit. It is based on the complementarity between a model-based approach accounting for uncertainties aimed at quantifying the degradation modes signatures and a data-driven approach aimed at recalibrating the healthy syndrome from measures. Because of the computational time costs of uncertainties propagation into the physics based model, a surrogate modeling technic called Kriging associated to Latin hypercube sampling is utilized. The hybrid approach is tested on a pumping unit of an aircraft engine and shows good results for computing the degradation modes signatures and performing their detection and identification

dynamic modelling of the swash plate of a hydraulic axial piston pump for condition monitoring applications

Abstract In the last years Prognostic and Health Management (PHM) has become one of the challenging topic in the engineering field. In particular, model-based approach for diagnostic relies on the development of a mathematical model of the system representing its flawless status. Once the model has been developed and carefully calibrated on experimental data referred to flawless pump condition the comparison between the model output and the real system output leads to the residual analysis, which gives a diagnosis of the component health. This paper presents the mathematical model of a hydraulic axial piston pump developed in order to replicate the dynamic behavior of the swash plate for PHM applications. The model has been developed on the basis of simplified hypotheses, a friction model between swash plate and bearings has been introduced. A detailed experimental activity was carried out to calibrate and validate the model with step tests and sweep tests. The comparison between numerical and experimental results shows a satisfying agreement and highlights the model capability to reproduce the swash plate dynamics. Future works will include tests with the pump in faulty conditions to evaluate the pump health state through the residual analysis of the swash plate position