The machine abnormal degree detection method based on SVDD and negative selection mechanism

As is well-known, fault samples are essential for the fault diagnosis and anomaly detection, but in most cases, it is difficult to obtain them. The negative selection mechanism of immune system, which can distinguish almost all nonself cells or molecules with only the self cells, gives us an inspiration to solve the problem of anomaly detection with only the normal samples. In this paper, we introduced the Support Vector Data Description (SVDD) and negative selection mechanism to separate the state space of machines into self, non-self and fault space. To estimate the abnormal level of machines, a function that could calculate the abnormal degree was constructed and its sensitivity change according to the change of abnormal degree was also discussed. At last, Iris-Fisher and ball bearing fault data set were used to verify the effectiveness of this method

Diagnosis of Fault Modes Masked by Control Loops with an Application to Autonomous Hovercraft Systems

This paper introduces a methodology for the design, testing and assessment of incipient failure detection techniques for failing components/systems of an autonomous vehicle masked or hidden by feedback control loops. It is recognized that the optimum operation of critical assets (aircraft, autonomous systems, etc.) may be compromised by feedback control loops by masking severe fault modes while compensating for typical disturbances. Detrimental consequences of such occurrences include the inability to detect expeditiously and accurately incipient failures, loss of control and inefficient operation of assets in the form of fuel overconsumption and adverse environmental impact. We pursue a systems engineering process to design, construct and test an autonomous hovercraft instrumented appropriately for improved autonomy. Hidden fault modes are detected with performance guarantees by invoking a Bayesian estimation approach called particle filtering. Simulation and experimental studies are employed to demonstrate the efficacy of the proposed methods

Underground distribution cable incipient fault diagnosis system

This dissertation presents a methodology for an efficient, non-destructive, and online incipient fault diagnosis system (IFDS) to detect underground cable incipient faults before they become catastrophic. The system provides vital information to help the operator with the decision-making process regarding the condition assessment of the underground cable. It incorporates advanced digital signal processing and pattern recognition methods to classify recorded data into designated classes. Additionally, the IFDS utilizes novel detection methodologies to detect when the cable is near failure. The classification functionality is achieved through employing an ensemble of rule-based and supervised classifiers. The Support Vector Machines, designed and used as a supervised classifier, was found to perform superior. In addition to the normalized energy features computed from wavelet packet analysis, two new features, namely Horizontal Severity Index, and Vertical Severity Index are defined and used in the classification problem. The detection functionality of the IFDS is achieved through incorporating a temporal severity measure and a detection method. The novel severity measure is based on the temporal analysis of arrival times of incipient abnormalities, which gives rise to a numeric index called the Global Severity Index (GSI). This index portrays the progressive degradation path of underground cable as catastrophic failure time approaches. The detection approach utilizes the numerical modeling capabilities of SOM as well as statistical change detection techniques. The natural logarithm of the chronologically ordered minimum modeling errors, computed from exposing feature vectors to a trained SOM, is used as the detection index. Three modified change detection algorithms, namely Cumulative Sum, Exponentially Weighted Moving Averages, and Generalized Likelihood Ratio, are introduced and applied to this application. These algorithms determine the change point or near failure time of cable from the instantaneous values of the detection index. Performance studies using field recorded data were conducted at three warning levels to assess the capability of the IFDS in predicting the faults that actually occurred in the monitored underground cable. The IFDS presents a high classification rate and satisfactory detection capability at each warning level. Specifically, it demonstrates that at least one detection technique successfully provides an early warning that a fault is imminent

Vibration Monitoring: Gearbox identification and faults detection

L'abstract è presente nell'allegato / the abstract is in the attachmen

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

Nonlinear fault detection and diagnosis using Kernel based techniques applied to a pilot distillation colomn

Fault detection and diagnosis is an important problem in process engineering. In this dissertation, use of multivariate techniques for fault detection and diagnosis is explored in the context of statistical process control. Principal component analysis and its extension, kernel principal component analysis, are proposed to extract features from process data. Kernel based methods have the ability to model nonlinear processes by forming higher dimensional representations of the data. Discriminant methods can be used to extend on feature extraction methods by increasing the isolation between different faults. This is shown to aid fault diagnosis. Linear and kernel discriminant analysis are proposed as fault diagnosis methods. Data from a pilot scale distillation column were used to explore the performance of the techniques. The models were trained with normal and faulty operating data. The models were tested with unseen and/or novel fault data. All the techniques demonstrated at least some fault detection and diagnosis ability. Linear PCA was particularly successful. This was mainly due to the ease of the training and the ability to relate the scores back to the input data. The attributes of these multivariate statistical techniques were compared to the goals of statistical process control and the desirable attributes of fault detection and diagnosis systems.Dissertation (MEng (Control Engineering))--University of Pretoria, 2008.Chemical EngineeringMEngUnrestricte

Novel deep cross-domain framework for fault diagnosis or rotary machinery in prognostics and health management

Improving the reliability of engineered systems is a crucial problem in many applications in various engineering fields, such as aerospace, nuclear energy, and water declination industries. This requires efficient and effective system health monitoring methods, including processing and analyzing massive machinery data to detect anomalies and performing diagnosis and prognosis. In recent years, deep learning has been a fast-growing field and has shown promising results for Prognostics and Health Management (PHM) in interpreting condition monitoring signals such as vibration, acoustic emission, and pressure due to its capacity to mine complex representations from raw data. This doctoral research provides a systematic review of state-of-the-art deep learning-based PHM frameworks, an empirical analysis on bearing fault diagnosis benchmarks, and a novel multi-source domain adaptation framework. It emphasizes the most recent trends within the field and presents the benefits and potentials of state-of-the-art deep neural networks for system health management. Besides, the limitations and challenges of the existing technologies are discussed, which leads to opportunities for future research. The empirical study of the benchmarks highlights the evaluation results of the existing models on bearing fault diagnosis benchmark datasets in terms of various performance metrics such as accuracy and training time. The result of the study is very important for comparing or testing new models. A novel multi-source domain adaptation framework for fault diagnosis of rotary machinery is also proposed, which aligns the domains in both feature-level and task-level. The proposed framework transfers the knowledge from multiple labeled source domains into a single unlabeled target domain by reducing the feature distribution discrepancy between the target domain and each source domain. Besides, the model can be easily reduced to a single-source domain adaptation problem. Also, the model can be readily updated to unsupervised domain adaptation problems in other fields such as image classification and image segmentation. Further, the proposed model is modified with a novel conditional weighting mechanism that aligns the class-conditional probability of the domains and reduces the effect of irrelevant source domain which is a critical issue in multi-source domain adaptation algorithms. The experimental verification results show the superiority of the proposed framework over state-of-the-art multi-source domain-adaptation models

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

30th International Conference on Condition Monitoring and Diagnostic Engineering Management (COMADEM 2017)

Proceedings of COMADEM 201

A Machine Learning approach for damage detection and localisation in Wind Turbine Gearbox Bearings

Increasing demand for renewable sources requires more cost-effective solutions to mitigate the cost of maintenance and produce more energy. Preventive maintenance is the most normally adopted scheme in industry for maintenance but despite being well accepted has severe limitations. Its inability to intelligently schedule maintenance at the right time and prevent unexpected breakdowns are the main downsides of this approach and consequently leads to several problems such as unnecessary maintenances. This strategy does not justify the additional costs and thereby represents a negative aspect for renewable energy resource companies that try to generate cost-competitive energy. These challenges are progressively leading towards the predictive maintenance approach to overcome these aforementioned issues. Wind Turbine Gearbox Bearings have received a lot of attention due to the high incidence failure rates provoked by the harsh operational and environmental conditions. Current techniques only reach a level one of diagnostics commonly known as the Novelty Detection stage and normally requires the expertise of a skilled operator to interpret data and infer damage from it. A data-driven approach by using Machine Learning methods has been used to tackle the damage detection and location stage in bearing components. The damage location was performed by using non-destructive methods such as the Acoustic Emission technique — these measurements were used as features to locate damage around the bearing component once the damage was detected. The implementation of this stages also led to the exploration of damage generation due to overload defects and proposed a methodology to simulate these defects in bearings — the study of this concept was implemented in a scaled-down experiment where damage detection and localisation was performed. Due to the importance of the implementation of a damage location stage, damage in AE sensors was also explored in this work. Features extracted from impedance curves allowed to train Machine Learning methods to trigger a novelty when a bonding scenario occurred. This ultimately allowed the identification of unhealthy sensors in the network that could potentially generate spurious results in the damage predictions stage