Domain Adaptive Transfer Learning for Fault Diagnosis

Thanks to digitization of industrial assets in fleets, the ambitious goal of transferring fault diagnosis models fromone machine to the other has raised great interest. Solving these domain adaptive transfer learning tasks has the potential to save large efforts on manually labeling data and modifying models for new machines in the same fleet. Although data-driven methods have shown great potential in fault diagnosis applications, their ability to generalize on new machines and new working conditions are limited because of their tendency to overfit to the training set in reality. One promising solution to this problem is to use domain adaptation techniques. It aims to improve model performance on the target new machine. Inspired by its successful implementation in computer vision, we introduced Domain-Adversarial Neural Networks (DANN) to our context, along with two other popular methods existing in previous fault diagnosis research. We then carefully justify the applicability of these methods in realistic fault diagnosis settings, and offer a unified experimental protocol for a fair comparison between domain adaptation methods for fault diagnosis problems.Comment: Presented at 2019 Prognostics and System Health Management Conference (PHM 2019) in Paris, Franc

A distributed networked approach for fault detection of large-scale systems

Networked systems present some key new challenges in the development of fault diagnosis architectures. This paper proposes a novel distributed networked fault detection methodology for large-scale interconnected systems. The proposed formulation incorporates a synchronization methodology with a filtering approach in order to reduce the effect of measurement noise and time delays on the fault detection performance. The proposed approach allows the monitoring of multi-rate systems, where asynchronous and delayed measurements are available. This is achieved through the development of a virtual sensor scheme with a model-based re-synchronization algorithm and a delay compensation strategy for distributed fault diagnostic units. The monitoring architecture exploits an adaptive approximator with learning capabilities for handling uncertainties in the interconnection dynamics. A consensus-based estimator with timevarying weights is introduced, for improving fault detectability in the case of variables shared among more than one subsystem. Furthermore, time-varying threshold functions are designed to prevent false-positive alarms. Analytical fault detectability sufficient conditions are derived and extensive simulation results are presented to illustrate the effectiveness of the distributed fault detection technique

AI-enabled modeling and monitoring of data-rich advanced manufacturing systems

The infrastructure of cyber-physical systems (CPS) is based on a meta-concept of cybermanufacturing systems (CMS) that synchronizes the Industrial Internet of Things (IIoTs), Cloud Computing, Industrial Control Systems (ICSs), and Big Data analytics in manufacturing operations. Artificial Intelligence (AI) can be incorporated to make intelligent decisions in the day-to-day operations of CMS. Cyberattack spaces in AI-based cybermanufacturing operations pose significant challenges, including unauthorized modification of systems, loss of historical data, destructive malware, software malfunctioning, etc. However, a cybersecurity framework can be implemented to prevent unauthorized access, theft, damage, or other harmful attacks on electronic equipment, networks, and sensitive data. The five main cybersecurity framework steps are divided into procedures and countermeasure efforts, including identifying, protecting, detecting, responding, and recovering. Given the major challenges in AI-enabled cybermanufacturing systems, three research objectives are proposed in this dissertation by incorporating cybersecurity frameworks. The first research aims to detect the in-situ additive manufacturing (AM) process authentication problem using high-volume video streaming data. A side-channel monitoring approach based on an in-situ optical imaging system is established, and a tensor-based layer-wise texture descriptor is constructed to describe the observed printing path. Subsequently, multilinear principal component analysis (MPCA) is leveraged to reduce the dimension of the tensor-based texture descriptor, and low-dimensional features can be extracted for detecting attack-induced alterations. The second research work seeks to address the high-volume data stream problems in multi-channel sensor fusion for diverse bearing fault diagnosis. This second approach proposes a new multi-channel sensor fusion method by integrating acoustics and vibration signals with different sampling rates and limited training data. The frequency-domain tensor is decomposed by MPCA, resulting in low-dimensional process features for diverse bearing fault diagnosis by incorporating a Neural Network classifier. By linking the second proposed method, the third research endeavor is aligned to recovery systems of multi-channel sensing signals when a substantial amount of missing data exists due to sensor malfunction or transmission issues. This study has leveraged a fully Bayesian CANDECOMP/PARAFAC (FBCP) factorization method that enables to capture of multi-linear interaction (channels × signals) among latent factors of sensor signals and imputes missing entries based on observed signals

Representation Learning based and Interpretable Reactor System Diagnosis Using Denoising Padded Autoencoder

With the mass construction of Gen III nuclear reactors, it is a popular trend to use deep learning (DL) techniques for fast and effective diagnosis of possible accidents. To overcome the common problems of previous work in diagnosing reactor accidents using deep learning theory, this paper proposes a diagnostic process that ensures robustness to noisy and crippled data and is interpretable. First, a novel Denoising Padded Autoencoder (DPAE) is proposed for representation extraction of monitoring data, with representation extractor still effective on disturbed data with signal-to-noise ratios up to 25.0 and monitoring data missing up to 40.0%. Secondly, a diagnostic framework using DPAE encoder for extraction of representations followed by shallow statistical learning algorithms is proposed, and such stepwise diagnostic approach is tested on disturbed datasets with 41.8% and 80.8% higher classification and regression task evaluation metrics, in comparison with the end-to-end diagnostic approaches. Finally, a hierarchical interpretation algorithm using SHAP and feature ablation is presented to analyze the importance of the input monitoring parameters and validate the effectiveness of the high importance parameters. The outcomes of this study provide a referential method for building robust and interpretable intelligent reactor anomaly diagnosis systems in scenarios with high safety requirements

Information Theory and Its Application in Machine Condition Monitoring

Condition monitoring of machinery is one of the most important aspects of many modern industries. With the rapid advancement of science and technology, machines are becoming increasingly complex. Moreover, an exponential increase of demand is leading an increasing requirement of machine output. As a result, in most modern industries, machines have to work for 24 hours a day. All these factors are leading to the deterioration of machine health in a higher rate than before. Breakdown of the key components of a machine such as bearing, gearbox or rollers can cause a catastrophic effect both in terms of financial and human costs. In this perspective, it is important not only to detect the fault at its earliest point of inception but necessary to design the overall monitoring process, such as fault classification, fault severity assessment and remaining useful life (RUL) prediction for better planning of the maintenance schedule. Information theory is one of the pioneer contributions of modern science that has evolved into various forms and algorithms over time. Due to its ability to address the non-linearity and non-stationarity of machine health deterioration, it has become a popular choice among researchers. Information theory is an effective technique for extracting features of machines under different health conditions. In this context, this book discusses the potential applications, research results and latest developments of information theory-based condition monitoring of machineries

Fault Diagnosis Of Sensor And Actuator Faults In Multi-Zone Hvac Systems

Globally, the buildings sector accounts for 30% of the energy consumption and more than 55% of the electricity demand. Specifically, the Heating, Ventilation, and Air Conditioning (HVAC) system is the most extensively operated component and it is responsible alone for 40% of the final building energy usage. HVAC systems are used to provide healthy and comfortable indoor conditions, and their main objective is to maintain the thermal comfort of occupants with minimum energy usage. HVAC systems include a considerable number of sensors, controlled actuators, and other components. They are at risk of malfunctioning or failure resulting in reduced efficiency, potential interference with the execution of supervision schemes, and equipment deterioration. Hence, Fault Diagnosis (FD) of HVAC systems is essential to improve their reliability, efficiency, and performance, and to provide preventive maintenance. In this thesis work, two neural network-based methods are proposed for sensor and actuator faults in a 3-zone HVAC system. For sensor faults, an online semi-supervised sensor data validation and fault diagnosis method using an Auto-Associative Neural Network (AANN) is developed. The method is based on the implementation of Nonlinear Principal Component Analysis (NPCA) using a Back-Propagation Neural Network (BPNN) and it demonstrates notable capability in sensor fault and inaccuracy correction, measurement noise reduction, missing sensor data replacement, and in both single and multiple sensor faults diagnosis. In addition, a novel on-line supervised multi-model approach for actuator fault diagnosis using Convolutional Neural Networks (CNNs) is developed for single actuator faults. It is based a data transformation in which the 1-dimensional data are configured into a 2-dimensional representation without the use of advanced signal processing techniques. The CNN-based actuator fault diagnosis approach demonstrates improved performance capability compared with the commonly used Machine Learning-based algorithms (i.e., Support Vector Machine and standard Neural Networks). The presented schemes are compared with other commonly used HVAC fault diagnosis methods for benchmarking and they are proven to be superior, effective, accurate, and reliable. The proposed approaches can be applied to large-scale buildings with additional zones