Outline of a fault diagnosis system for a large-scale board machine

Global competition forces process industries to continuously optimize plant operation. One of the latest trends for efficiency and plant availability improvement is to set up fault diagnosis and maintenance systems for online industrial use. This paper presents a methodology for developing industrial fault detection and diagnosis (FDD) systems. Since model or data-based diagnosis of all components cannot be achieved online on a large-scale basis, the focus must be narrowed down to the most likely faulty components responsible for abnormal process behavior. One of the key elements here is fault analysis. The paper describes and briefly discusses also other development phases, process decomposition, and the selection of FDD methods. The paper ends with an FDD case study of a large-scale industrial board machine including a description of the fault analysis and FDD algorithms for the resulting focus areas. Finally, the testing and validation results are presented and discussed.Peer reviewe

Diagnosis of airspeed measurement faults for unmanned aerial vehicles

Airspeed sensor faults are common causes for incidents with unmanned aerial vehicles with pitot tube clogging or icing being the most common causes. Timely diagnosis of such faults or other artifacts in signals from airspeed sensing systems could potentially prevent crashes. This paper employs parameter adaptive estimators to provide analytical redundancies and a dedicated diagnosis scheme is designed. Robustness is investigated on sets of flight data to estimate distributions of test statistics. The result is robust diagnosis with adequate balance between false alarm rate and fault detectability

Adaptive Estimation and Detection Techniques with Applications

Hybrid systems have been identified as one of the main directions in control theory and attracted increasing attention in recent years due to their huge diversity of engineering applications. Multiplemodel (MM) estimation is the state-of-the-art approach to many hybrid estimation problems. Existing MM methods with fixed structure usually perform well for problems that can be handled by a small set of models. However, their performance is limited when the required number of models to achieve a satisfactory accuracy is large due to time evolution of the true mode over a large continuous space. In this research, variable-structure multiple model (VSMM) estimation was investigated, further developed and evaluated. A fundamental solution for on-line adaptation of model sets was developed as well as several VSMM algorithms. These algorithms have been successfully applied to the fields of fault detection and identification as well as target tracking in this thesis. In particular, an integrated framework to detect, identify and estimate failures is developed based on the VSMM. It can handle sequential failures and multiple failures by sensors or actuators. Fault detection and target maneuver detection can be formulated as change-point detection problems in statistics. It is of great importance to have the quickest detection of such mode changes in a hybrid system. Traditional maneuver detectors based on simplistic models are not optimal and are computationally demanding due to the requirement of batch processing. In this presentation, a general sequential testing procedure is proposed for maneuver detection based on advanced sequential tests. It uses a likelihood marginalization technique to cope with the difficulty that the target accelerations are unknown. The approach essentially utilizes a priori information about the accelerations in typical tracking engagements and thus allows improved detection performance. The proposed approach is applicable to change-point detection problems under similar formulation, such as fault detection

Adaptive Estimation and Detection Techniques with Applications

Hybrid systems have been identified as one of the main directions in control theory and attracted increasing attention in recent years due to their huge diversity of engineering applications. Multiplemodel (MM) estimation is the state-of-the-art approach to many hybrid estimation problems. Existing MM methods with fixed structure usually perform well for problems that can be handled by a small set of models. However, their performance is limited when the required number of models to achieve a satisfactory accuracy is large due to time evolution of the true mode over a large continuous space. In this research, variable-structure multiple model (VSMM) estimation was investigated, further developed and evaluated. A fundamental solution for on-line adaptation of model sets was developed as well as several VSMM algorithms. These algorithms have been successfully applied to the fields of fault detection and identification as well as target tracking in this thesis. In particular, an integrated framework to detect, identify and estimate failures is developed based on the VSMM. It can handle sequential failures and multiple failures by sensors or actuators. Fault detection and target maneuver detection can be formulated as change-point detection problems in statistics. It is of great importance to have the quickest detection of such mode changes in a hybrid system. Traditional maneuver detectors based on simplistic models are not optimal and are computationally demanding due to the requirement of batch processing. In this presentation, a general sequential testing procedure is proposed for maneuver detection based on advanced sequential tests. It uses a likelihood marginalization technique to cope with the difficulty that the target accelerations are unknown. The approach essentially utilizes a priori information about the accelerations in typical tracking engagements and thus allows improved detection performance. The proposed approach is applicable to change-point detection problems under similar formulation, such as fault detection

The challenge of advanced model-based fdir techniques for aerospace systems: the 2011 situation

For aerospace systems, advanced model-based Fault Detection, Identification, and Recovery (FDIR) challenges range from predesign and design stages for upcoming and new programs up to the improvement of the performance of in-service flying systems. However, today, their application to real aerospace world has remained extremely limited. The paper underlines the reasons for a widening gap between the advanced scientific FDIR methods being developed by the academic community and technological solutions demanded by the aerospace industry

Mooring System Diagnosis and Structural Reliability Control for Position Moored Vessels

Early diagnosis and fault-tolerant control are essential for safe operation of floating platforms where mooring systems maintain vessel position and must withstand environmental loads. This paper considers two critical faults, line breakage and loss of a buoyancy element and employs vector statistical change detection for timely diagnosis of faults. Diagnosis design is scrutinized and a procedure is proposed based on specified false alarm probability and estimation of the distribution of the test statistics on which change detection is based. A structural reliability index is applied for monitoring the safety level of each mooring line and, a set-point chasing algorithm accommodates the effects of line failure, as an integral part of the reliability-based set-point chasing control algorithm. The feasibility of the diagnosis and of the fault-tolerant control strategy is verified in model basin tests

Fault detection by segment evaluation based on inferential statistics for asset monitoring

Detection of unexpected events (e.g. anomalies and faults) from monitoring data is very challenging in machine health assessment. Hence, abrupt or incipient fault detection from the monitoring data is very crucial to increase asset safety, availability and reliability. This paper presents a generic methodology for abrupt and incipient fault detection and feature fusion for health assessment of complex systems. Proposed methodology consists of feature extraction, feature fusion, segmentation and fault detection steps. First of all, different features are extracted using descriptive statistics. Secondly, based on linearly weighted data fusion algorithm, extracted features are combined to get the generic and representative feature. Afterward, combined feature is divided into homogeneous segments by sliding window segmentation algorithm. Finally, each segment is further evaluated by coefficient of variability which is used in inferential statistics, to evaluate health state changes that indicate asset faults. To illustrate its effectiveness, the methodology is implemented on point machine and Li-ion battery monitoring data to detect abrupt and incipient faults. The results show that proposed methodology can be effectively used in fault detection for asset monitoring