industrial processes - uta talks 2017/diag prog 15.pdfchina education ministry project 111...

Moncrief-O’Donnell Chair, UTA Research Institute (UTARI)The University of Texas at Arlington, USA

and

F.L. Lewis, NAI

Talk available online at http://www.UTA.edu/UTARI/acs

Data‐driven Diagnostics and Prognostics forIndustrial Processes

Supported by :China Qian Ren Program, NEUChina Education Ministry Project 111 (No.B08015)

Qian Ren Consulting Professor, State Key Laboratory of Synthetical Automation for Process Industries,

Northeastern University, Shenyang, China

US NSF

ONR – Marc SteinbergUS TARDEC

Dr. George Vachtsevanoshttp://icsl.gatech.edu/icsl

ProfessorSystems and Controls, and Bioengineering

Phone: 404.894.6252 Fax: 404.894.7583 Office: VL E392

Email [email protected] Control Systems Laboratory

Great Minds Think Differently

John Wiley, New York, 2006 John Wiley, New York, 2003

Objectives Extend equipment lifetime Reduce down time Keep throughput and due dates on track – mission criticality Use minimum of maintenance personnel Maximum uptime for minimum effective maintenance costs CBM should be transparent to the user

No extra maintenance for the CBM network! Determine the best time to do maintenance

Efficiently use maintenance & repair resourcesDo not interfere with machine usage requirements

Allow planning for maintenance costsNo unexpected last-minute costs!

Condition-Based Maintenance (CBM)Prognostics & Health Management (PHM)

Condition Monitoring and Diagnostics of Machines

A SYSTEMS APPROACH TO CBM / PHM

The CBM/PHM Cycle

MachineSensors

Pre-Processing

FeatureExtraction

FaultClassification

Predictionof Fault

EvolutionData

ScheduleRequired

Maintenance

Systems &Signal processing

Diagnostics Prognostics MaintenanceScheduling

Identify importantfeatures

Fault Mode Analysis

Machine legacy failure data

Available resourcesRULMission due dates

Required Background Studies

PHM CBM

SelectSensors!

Systems Approach to Intelligent Diagnosis & Prognosis


Off Line- Background Studies, Fault Mode Analysis On Line- Perform real-time Fault Monitoring & Diagnosis

Two Phases of CBM Diagnostics

Three Stages of CBM/PHM

Diagnostics Prognostics Maintenance Scheduling

Diagnostics

• Fault (Failure) Detection

• Fault (Failure) Isolation

• Fault (Failure) Identification

Exception Fault Failure

CBM – Fault Diagnosis Background Studies

• Fault Mode Analysis (FMA) - Identify Failure and Fault Modes

• Identify the best Features to track for effective diagnosis

• Identify measured sensor outputs needed to compute the features

• Build Fault Pattern Library

Deal with FAULTSNeed to identify Faults before they become Failures

Phase I- Preliminary Off Line Studies

Why Motors Fail? Bearing Failures:

– Root cause of ~ 50%Motor Failures– Effect: Motor burn out– Sources: Improper Lubrication, Shaft Voltages, Excessive Loadings

Excessive Vibrations:– Effect: bearing failures, metal fatigue of parts and windings– Sources: Usually caused by improper balance of rotating part

Electrical Problems:– Effect: Higher than normal current, overheating– Sources: Low Voltages, Unbalanced 3-Phase Voltages

Mechanical Problems:– Effect: Bearing failures, overheating– Sources: Excessive Load and Load Fluctuations result in more current

Maintenance issues:– Sources: Inadequate regular maintenance, lack of preventive maintenance, lack of

Root Cause Analysis

Fault Mode Analysis Dr. George Vachtsevanoshttp://icsl.gatech.edu/icsl

Compressor Pre-rotation Vane

Condenser

Evaporator

•Compressor Stall & Surge•Shaft Seal Leakage•Oil Level High/Low•Aux. Pump Fail•Oil Cooler Fail•PRV/VGD Mechanical Failure

•Condenser Tube Fouling•Condenser Water Control Valve Failure•Tube Leakage•Decreased Sea Water Flow

•Target Flow Meter Failure•Decreased Chilled Water Flow•Evaporator Tube Freezing

•Non Condensable Gas in Refrigerant•Contaminated Refrigerant•Refrigerant Charge High•Refrigerant Charge Low

•SW in/out temp.•SW flow•Cond. press.•Cond. PD press.•Cond. liquid out temp.

•Comp. suct. press./temp.•Comp. disch. press./temp.•Comp. oil press./flow (at required points)•Comp. bearing oil temp•Comp. suct. super-heat•Shaft seal interface temp.•PRV Position

•Liquid line temp.•(Refrigerant weight)

•CW in/out temp./flow•Eva. temp./press.•Eva. PD press.

Ex. - Navy Centrifugal Chiller Failure Modes

Fault Mode AnalysisDr. George Vachtsevanoshttp://icsl.gatech.edu/icsl

Fault Mode: Refrigerant Charge Low

Symptoms: 1. Low Evaporator Liquid Temperature2. Low Evaporator Suction pressure3. Increasing difference (D-ELT-CWDT) between Chilled Water

Discharge Temperature and Evaporator Liquid Temperature

Sensors: 1. Evaporator Liquid Temperature (ELT)2. Evaporator Suction Pressure (ESP)3. Chilled Water Discharge Temperature (CWDT)


Failure Modes and Effects Criticality Analysis

Failure Modes and Effects Criticality Analysis

New systematic approach based on fuzzy Petri networks and efficient search techniques to define failure effect – root cause relationships

Large LeakDetected (0.9)

Ok (0.9)Not ok (0.1)

CheckPressure Meter

CheckVacuum Pump

Check forOverheating

Check forDirty Fluid

(0.81)

Ok (0.9)

Ok (0.8)

Ok (0.1)

Not ok (0.1)

Not ok (0.2)

Not ok (0.9)

Large Leak While Meter Readingis Correct (0.81)


Helicopter Fault Tree

HelicopterFailure

MotorFailures

ActuatorFailures

PowerFailures

SensorFailures

Computer SystemFailures

Main RotorFailures

Tail RotorFailures


Motor Fault Tree

MotorFailure

Gear BoxFailure

InternalMotorFailure

LocalPower Lines

Fail

GearsSlip

WearOn

Gears


Sensor Selection

• Existing OEM sensors

• Used e.g. for Control

• Add extra DSP – Virtual Sensors

• Add additional sensors for CBM/PHM

Feature Selection

• What to measure to get information about the fault?

Example- Jay Lee, Unic CincinnatiXerox machine- paper jam sensorUse Door open switch !!

SENSOR SELECTION AND PLACEMENT

• Objective: Determine the optimum type and placement of sensors

• Current Status:Ad hoc;heuristic methods;Mostly “an art”

• Future Direction: Put some “science” into the problem


DIAGNOSTICS • Model-Based Methods• Non-Model-Based – Data-Based• Statistical Analysis Methods

Fault Modes of an Electro-Hydraulic Flight Actuator

V. Skormin, 1994SUNY Binghamton

bearingcontrol surface

hydrauliccylinder

pump

poweramplifier

Fault Modes

Control surface lossExcessive bearing friction

Hydraulic system leakageAir in hydraulic systemExcessive cylinder frictionMalfunction of pump control valve

Rotor mechanical damageMotor magnetism loss

motor

Fault Mode Analysis

Use Physics of Failure and Failure Models to select failure features to include in feature vectors

Select Fault ID Feature Vector

Method 1- Dynamical System Diagnostic Models

The Fault Feature Vector is a sufficient statistic for identifying existing fault modes and conditions

BJssTs

1)()(motor dynamics

sBsMsFsX

pp )(1

)()(

pump/piston dynamics

LsKAsR

sP

)(

1)()(

2actuator system dynamics

Physical parameters are J, B, Mp, Bp, K, L


Select Feature VectorRelate physical parameters J, B, Mp, Bp, K, L to fault modes

Get expert opinion (from manufacturer or from user group) Get actual fault/failure legacy data from recorded machine histories Or run system testbed under induced faults

Result -

Condition Fault ModeIF (leakage coeff. L is large) THEN (fault is hydraulic system leakage)IF (motor damping coeff. B is large)AND (piston damping coeff. Bp is large)

THEN (fault is excess cylinder friction)

IF (actuator stiffness K is small)AND (piston damping coeff. Bp is small)

THEN (fault is air in hydraulic system)

Etc. Etc.

Therefore, select the physical parameters as the feature vectorT

pp LKBMBJt ][)(


Select Sensors for the Best Outputs to Measure


Tpp LKBMBJt ][)(

Cannot directly measure the feature vector

Can measure the inputs and outputs of the dynamical blocks, e.g.

BJssTs

1)()(

)(2

)()( tPDtCItT

(t)motor speed

armaturecurrent I(t)

pressuredifference P(t)

Therefore, use system identification techniques to estimate the features

Virtual Sensors = physical sensors + signal processing se

nsor

sDSP

signals from machine

Fault IDfeatures

BUT- There Ain’t no such thing as a Physical Parameter Meter

Method 2- Non-Model-Based Techniques


Condition Fault ModeIF (base mount vibration energy is large) THEN (fault is unbalance)IF (shaft vibration second mode is large)AND (motor vibration RMS value is large)

THEN (fault is gear tooth wear)

IF (third harmonic of shaft speed is present)AND (kurtosis of load vibration is large)

THEN (fault is worn outer ball bearing)

Etc. Etc.

Therefore, include vibration moments and frequencies in the feature vector

)(t [ time signals … frequency signals ]T

Get expert opinion (from manufacturer or from user group) Get actual fault/failure legacy data from recorded machine histories Or run system testbed under induced faults

More about DSP later

Method 3- Statistical Regression Techniques


Vibration magnitude

Driv

e tra

in g

ear t

ooth

wea

r

Principal Component AnalysisPearson’s correlationNonlinear correlation techniquesMultivariable regression

Clustering techniquesNeural networksStatistical

Fault 1

Fault 2

Fault 3

outliers

Condition Fault ModeIF (leakage coeff. L is large) THEN (fault is hydraulic system leakage)IF (motor damping coeff. B is large)AND (piston damping coeff. Bp is large)

THEN (fault is excess cylinder friction)

IF (actuator stiffness K is small)AND (piston damping coeff. Bp is small)

THEN (fault is air in hydraulic system)

Etc. Etc.

Fault Pattern Library

Condition Fault ModeIF (base mount vibration energy is large) THEN (fault is unbalance)IF (shaft vibration second mode is large)AND (motor vibration RMS value is large)

THEN (fault is gear tooth wear)

IF (third harmonic of shaft speed is present)AND (kurtosis of load vibration is large)

THEN (fault is worn outer ball bearing)

Etc. Etc.

)(t [ time signals … frequency signals ]T

Jay LeeUniv. Cincinnati

Bearing 1

Bearing 2

shaft

Base mount rear

Base mount front

0

1

Health status0= failure1= healthy

Multidimensional feature vector visualization-- Failure Radar Screen

Indicates correlated faults

Bearing 1

Bearing 2

shaft

Base mount rear

Base mount front

0

1

CBM Fault DIAGNOSTICS Procedure

machines

Math models

),,(),,(

uxhyuxfx

System Identification-Kalman filterNN system ID

RLS, LSE

Dig. Signal Processing

PhysicalParameterestimates &Aero. coeff.estimates

Sensoroutputs

VibrationMoments, FFT

FeatureVectors-

Sufficientstatistics

)(tFault ClassificationFeature patterns for faultsDecision fusion could use:

Fuzzy LogicExpert SystemsNN classifier

Stored Legacy Failure dataStatistics analysis

Feature extraction -determine inputs for Fault Classification

Physics of failureSystem dynamicsPhysical params.

Identify Faults/Failures

More info needed?

Inject probe test signals for refined diagnosisInformpilotyes

Serious?

Informpilot

yes

SensingFault Feature Extraction

Reasoning& Diagnosis

Systems, DSP& Data Fusion

SensorFusion

Featurevectors

Featurefusion

StoredFault Pattern

Library

Model-BasedDiagnosis

Set Decision ThresholdsManuf. variability dataUsage variabilityMission historyMinimize Pr{false alarm}Baseline perf. requirements

Phase II- On Line Fault Monitoring and Diagnostics

no

Request Maintenance

FAULT CLASSIFICATION

Fault Classification

Decision-MakingFault Classification

StoredFault Pattern

Library

Feature Vectors

)(t

Diagnosed Faults

Model-Based Reasoning (MBR) vs. Case-Based Reasoning

Too complex!Faults depend on Operating conditions

Neural networksFuzzy logicExpert system rulebaseBayesianDempster-ShaferModel-Based Reasoning

Decision-Making

N

i

n

jjij

N

i

n

jjij

i

x

xzxf

1 1

1 1

)(

)()(

IF (BM is negative medium) and (LC is negative small)

THEN (fault is air contamination)

IF (BM is positive) and (LC is normal) THEN (fault is water contamination)

IF (BM is normal) and (LC is positive medium)

THEN (fault is excessive leakage)

iii

iii PP

PPP

)()/()()/(

)/(

0

)(1

)(

)(

j

ij

Sjj

Sjj

i Sm

Sm

Bel

Bayes Probability

Dempster-Shafer Rules of Evidence

Expert & Rule-Based systems

Fuzzy LogicFuzzy logic unifies ALL these approaches

Bayesian Classifier Performance

normal abnormal

FN FPdecision criterion

False positiveFalse negative

Prob. of False Alarm

Decision threshold

Hypothesistesting

ji

ji

BAji

CBAji

BmAm

BmAmCmm

)()(1

)()()(

21

21

21

Dempster-Shafer• If m1 and m2 are two pieces of Evidence, the combined

Evidence is given by

Conflict between two pieces of evidence

• Based on this, can compute:• Belief – C is definitely true. Bel(C)= • Plausibility – C may be true. Pl(C)=

CD

Dm )(

0

)(CD

Dm

In Bayes, Bel= Pl

Dempster-Shafer Example

Suppose there are 100 cars in a parking lot consisting of type A (red) and B (green). Two policemen count the type of cars in the lot. • First policeman m1 says that there are 30 A cars and 20 B cars. • Second policeman m2 says that there are 20 A cars and 20 cars that could A or B.

m1(A)0.3

m1(B)0.2

m1(θ)0.5

m2(A) 0.2

0.06 0.04 (0 intersection)CONFLICT

0.1

m2(AB) 0.2

0.06 0.04 0.1

m2(θ) 0.6

0.18 0.12 0.3

So there are between 42 and 83 cars of type Abetween 17 and 58 cars of type B

Bel(A)=m12(A)=0.42. (42 A cars)Bel(B)=m12(B)=0.17. (17 B cars)

Pl(A)= m12(A)+m12(AB)+m12(θ)=0.83. (83 A cars)Pl(B)= m12(B)+m12(AB)+m12(θ)=0.58. (58 B cars)

Using the formulas above:

Fuzzy Logic Fault ClassificationUnifies

expert systemsstatisticalneural network approaches

2-D FL system c.f. neural network

Fig 1 FL rulebase to diagnose broken bars in motor drives using sideband components of vibration signature FFT [Filippetti 2000].

Number of broken bars = none, one, two.Incip. = incipient fault

small medium large

smal

lm

ediu

mla

rge

Sideband component I1

Side

band

com

pone

nt I 2

none incip.

incip.

one

one

one

oneortwo

oneortwo

two

... ..

.........

.................... .

......... . . . ...... .

.. ..

.

. ..

Fig 5 Clustering of statistical fault data

Vibration magnitude

Driv

e tra

in g

ear t

ooth

wea

r

Faul

t con

ditio

ns

one

two

thre

e

low med severe

FL Decision Thresholds

From Harold Chestnut

Based onLegacy fault data historiesManuf. variability dataUsage variabilityMission historyMinimize Pr{false alarm}Baseline perf. requirements

Can be tuned using adaptive learning techniques

Two-Layer Neural Network

(.)

(.)

(.)

(.)

x1

x2

y1

y2

VT WT

inputs

hidden layer

outputs

xn ym

1

2

3

L

Neural Networks

)( xVWy TT

1-layer NN has W= I

)( xVy T

2-layer NN

RVFL NN has V= random

Training1-layer – Gradient Descent XekVkV T )()1(

Where X= input pattern vectorsY= output target vectors

)(kyYe = training error

Multilayer- backpropagation (Paul Werbos)

Neural Networks - ClassificationGroup 1: o (1,1), (1,2)Group 2: x (2,-1), (2, -2)Group 3: + (-1,2), (-2,1)Group 4: # (-1,-1), (-2,-2)

Classify 8 points into two groups

-3 -2 -1 0 1 2 3-3

-2

-1

0

1

2

3

oo

xx

++

##

Represent the 4 groups as 00, 01, 10, 11Then, the input pattern vector and target vector are

2112212121212211

X

1100110011110000

Y

I. Training

MATLAB CodeR=[-2 2;-2 2]; % define 2-D input spacenetp=newp(R,2); % define 2-neuron NNp1=[1 1]'; p2=[1 2]'; p3=[2 -1]'; p4=[2 -2]'; p5=[-1 2]'; p6=[-2 1]'; p7=[-1 -1]'; p8=[-2 -2]‘;t1=[0 0]'; t2=[0 0]'; t3=[0 1]'; t4=[0 1]'; t5=[1 0]'; t6=[1 0]'; t7=[1 1]'; t8=[1 1]‘;P=[p1 p2 p3 p4 p5 p6 p7 p8];T=[t1 t2 t3 t4 t5 t6 t7 t8];netp.trainParam.epochs = 20; % train for max 20 epochsnetp = train(netp,P,T);

01

2113

xy T

result

Result after training

Defines 2 lines in (x1, x2) plane

II. Classification (simulation)All points are classified into one of the 4 regions

Y1=sim(netp,P1)

Clustering Using NNCompetitive NN

Make 2 x 80 matrix P of the 80 points

Given80 datapoints

MATLAB code% make new competitive NN with 8 neurons

net = newc([0 1;0 1],8,.1); % train NN with Kohonen learning

net.trainParam.epochs = 7; net = train(net,P); w = net.IW{1};

%plotplot(P(1,:),P(2,:),'+r');xlabel('p(1)');ylabel('p(2)');hold on;circles = plot(w(:,1),w(:,2),'ob');

I. Training & Clustering

II. Classification (simulation)p = [0; 0.2];a = sim(net,p)

Activates neuron number 1

Possible failures depend on current operating mode

Model-Based ReasoningMBR


Model Legend -Condition Function

SensorComponent

BlockDiagram

MBRModel

MBR Approach Provides Multiple Benefits and Functions:– Intuitive, Multi-Level Modeling– Inherent Cross Checking for False Alarm Mitigation– Multi-Level Correlation for Failure Isolation Advantage

Chains of Functions Indicate Functional Flows.– Components Link to the Functions They Support.– Sensors Link to the Functions They Monitor.– Conditions Link to the Functions They Control.

Michael Gandy and Kevin LineLockheed Martin AeronauticsModel-Based Reasoning (MBR) Provides a

Significant Part of PHM Design Solution

Shi nian shu muBai nian shu ren

Keshi-Wu nian shu xuesheng

十年树木，百年树人

PROGNOSTICS

The CBM/PHM Cycle

MachineSensors

Pre-Processing

FeatureExtraction

FaultClassi-fication

Predictionof Fault

EvolutionData

ScheduleRequired

Maintenance

Systems &Signal processing

Diagnostics PrescriptionMaintenanceScheduling

PrescribeMaintenance

Prognostics

Current fault condition

Required Background Studies

Machine legacy failure data

Available resourcesRULMission due dates

PHMPrognostics

Prescription Libraryfailure modestrendsside effects

Rulebase expert systemFuzzy/Neural SystemPrescription decision treeBayesianDempster-Shafer

DiagnosticFaultcondition

Maint. Request

Maint. Planning & Schedulingweight maint. Requests

Computer machine plannersHTN, etc.

Performance Priority Measuresearliest mission dateleast slack repair timedue date

RULEstimated time of failure

Mission criticality and due date requirements

Maintenance Requirements Planning

Maintenance PrioritiesMission Due Dates

safetyriskcost

opportunityconvenience

Automatically generated work orders.Maintenance plan with maint. Rankings

Resource assignmentand dispatchingpriority dispatchingmaximum % utilizationminimize bottlenecks

resources

PrioritizedWork Ordersassigned toMaint. Units

Guaranteed QoS

User interfaces forDecision assistanceDecision Support

Adaptiveintegrationof newprescriptions

PHM Maintenance Prescription and Scheduling Procedure

StoredPrescription

Library

Medical HealthPrescriptions Manufacturing MRP

Communications SystemScheduling & Routing

ManufacturingOn-Line ResourceDispatching

Prescription-Based Health Management System (PBHMS)

Generate:optimized maint. tasks(c.f. PMS cards)

Prescription

Scheduling

Priority Costs

Dispatching

Fault detection threshold

4%fault

10%fault

failure

ReplaceComponent

Replacesubsystem Replace entire

system

Fault development trend:Progressive escalation of required maintenance

Repair time

Missiondue date

Startrepair

Removefromservice

Estimatedtime of Failure (ETF)

Scheduling Removal From Service and Start of Repair in terms of ETF and Mission Due Date

Prognostics- Why?

I. Fault Propagation & Progression

II. Time of Failure &Remaining Useful Life (RUL)

Impacts the Prescription Impacts the Scheduling

N. Viswanadham

RUL

Presenttime

Progressive Escalation Mission Criticality

Extension of manufacturing MRP

Off Line- Background Studies, RUL Analysis On Line- Perform real-time Prognostics & RUL

Two Phases of Prognostics & RUL

Four Stages of CBM/PHM Diagnostics Prognostics & RUL Maintenance Prescription Maintenance Scheduling

PHM – Fault Prognostics & RUL Background Studies

• Fault Mode Time Analysis- Identify MTTF in each fault condition

• Identify the best Feature Combinations to track for effective prognosis & RUL

• Identify Best Decision Schemes to compute the feature combinations

• Build Failure Time Pattern Library

Deal with Mean Time to Failure in each Fault condition.ALSO require Confidence Limits

Phase I- Preliminary Off-Line Studies

PROGNOSTICS

Hazard Function-Probability of failure at current time

tWearin-Earlymortality

Wearout

Trend Analysis & Prediction-Track Feature vector trendsStudy and)(t )(t

t

)(tNormal operatingregion

Fault tolerance limits

Fault tolerance limits found by legacy data statistics

Estimate Remaining Useful Life with Confidence IntervalsLegacy Data Statistics gives MTBF, MTTF etc.

Based on legacy failure data

- H. Chestnut

.

..

. ....

. .....

... ..

....

.............

...... .. . . . ...... .

.. .

.

.

. ..

Sample of legacy statistical fault dataVibration magnitudeD

rive

train

gea

r too

th w

ear

failure .

.

. ..

. . ..

.... . . . . . . .. .. .....

.... .

. ..

. . . .. . . . .. .

. . ...... ..

.

.

..

.

Sample of legacy statistical RUL dataVibration magnitude

Use

ful R

emai

ng L

ife

0

Stored Legacy Failure data Statistics analysis

Find MTTF for given fault conditionand find confidence limits

. . ....

...

. . . ...... ..

. ..

... . .

....

... . . . ...... .

.. .

.

... . ..

....

.. . . ...... .

..

..

Statistical RegressionClusteringNeural network classification

• Variations of available empirical and deterministic fatigue crack propagation models are based on Paris’ formula:

Where:α = instantaneous length of dominant crackΝ = running cyclesCo, n = material dependent constantsΔК = range of stress intensity factor over one loading cycle

no KCdNda

e.g. Deterministic Crack Propagation Models

OR- Physical Modeling


Andy Hess, US Naval Air

Estimation of Failure Probability Density FunctionsGives best estimate of RUL (conditional mean) as well as confidence limits

A priori failure PDF A posteriori conditional failure PDFgiven no failure through present time

Present timeExpected remaining life

RUL confidence limitst

Remaining life PDF

Expected remaining life

Present time

5%95%

t

t

Lead-timeinterval

JITP

Removal From Service-Just In Time Point (JITP) avoids 95% of failures

Andy Hess, US Naval Air

RUL PDFs as a Function of Time

timeExpected RUL

RUL estimates become more accurate and precise as RUL decreases

a priori RUL PDF

Expected failure time

95% confidencelimits

Kalman Filter is the optimal estimator for the conditional PDF for linear Gaussian case-gives estimate plus

covariance

t

)(tNormal operatingregion

Fault tolerance limits

Confidence limits

Estimated feature

alarm

failure

Minimize Pr{false alarm}Pr{miss}

Model-Based Predictive Methods- Mike Grimble

Fault Trend Analysis

The Confidence Prediction Neural Network (CPNN)

• For CPNN, each node assigns a weight (degree of confidence) for an input X and a candidate output Yi.

• Final output is the weighted sum of all candidate outputs.

• In addition to the final output, the confidence distribution of that output can be computed as

2

21

( )1 1( , ) ( , ) exp[ ](2 ) 2

li

iiCD CD

Y YCD Y C Yl

X X

Input layer

Patternlayer

Summationlayer

output

Numerator Denominator

Confidencedistribution

approximator

CPNN


CONDITION-BASED MAINTENANCE (CBM)

CBM- Prescription of Maintenance

Decision-MakingPrescription

StoredPrescription

Library

Fault condition Maintenance Prescription

Neural networksFuzzy logicExpert system rulebaseBayesianDempster-Shafer

Model-Based Reasoning (MBR) for Fault Progression?

Prescription may change if fault worsens

FaultTrend??

Diagnosis Prescription

IF (leakage coefficient is excessive) THEN (Replace hydraulic pump)

IF (piston friction is excessive) THEN (Replace hydraulic pump)

IF (excessive bearing wear) THEN (replace motor)

IF(exc. piston friction) AND (exc. bearing wear)

THEN (replace hydraulic pump/motor assembly)

Prescription Library

Side Effects?Equipment down timeImpact on related systemsMission failureUse of critical maintenance resources or parts

Dual‐Use Tech Transfer to IndustryJohn Gan, SIMTech, and C.K. Pang, NUS

Dual-Use Leveraging Funding:DARPA SBIR I- Control of UAVNSF- Cooperative Games: Applications to Microgrid

Dual-Use Tech Transfer to Industry:Singapore Manufacturing Inst.Dynamic Resource Assignment forEnergy-Aware Manufacturing

Journal Papers1. C.K. Pang, G. Hudas, M. Middleton, C.V. Le, O.P. Gan, and

F.L. Lewis, "Discrete Event Command and Control forNetworked Teams with Multiple Military Missions" J. DefenseModeling and Simulation, 2011.

2. C.K. Pang, G.R. Hudas, D.G. Mikulski, C.V. Le, and F.L.Lewis, “Command and control for large-scale hybrid warfaresystems,” Unmanned Systems, Jan 2015.

3. Y.Y. Joe, O.P. Gan, and F.L. Lewis, “Multi-commodity flowdynamic resource assignment and matrix-based jobdispatching for multi-relay transfer in complex materialhandling systems (MHS),” J. Intelligent manufacturing, toappear, 2012.

Best Application Paper Award, Asian Control Conf.

2011C.K. Pang, J.H. Zhou, Z.W. Zhong and F.L. Lewis, “IndustrialFault Detection and Isolation Using Dominant FeatureIdentification,” Proc. Asian Control Conf., pp. 1018-1023,Kaohsiung, Taiwan, May 2011.

High speed milling machine

Wireless Sensor Networks

• Machinery monitoring & Condition-Based Maintenance (CBM / PHM / RUL)

• Personnel monitoring and secure area denial

$180K in ARO/ UTA/ Texas funding to set up ARRI WSN lab $240K in MEMS & Network related Grants from NSF and ARO

Contact Frank [email protected]://arri.uta.edu/acs

C&C UserInterface forwireless networks-

WirelessData Collection Networks

Wireless Sensor

Machine Monitoring

Security Personnel and Vehicle Monitoring

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HC

O O

H

CO O

H h+

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

e-

e-

e-

e-

TiO2TiO2

Ni

Biochemical Monitoring

EnvironmentalMonitoring

WirelessData Collection Networks

Wireless Sensor

Machine Monitoring

Security Personnel and Vehicle Monitoring

C

O O

HH2O

h+

h+

h+

H2OC

O O

H

C

O O

H

C

O O

HC

O O

H h+

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

e-

e-

e-

e-

TiO2TiO2

Ni

C

O O

H

C

O O

HH2O

h+

h+h+

h+

H2OC

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

HC

O O

H

CO O

H h+

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

C

O O

H

e-

e-

e-

e-

TiO2TiO2

Ni

Biochemical Monitoring

EnvironmentalMonitoring

Microstrain V-Link

Transceiver

MicrostrainTransceiver

Connect to PC

MicrostrainG-Sensor

Microstrain Wireless Sensorshttp://www.microstrain.com/index.cfm

V-link – 4 voltage inputs for any sensors that vary voltageG-link – accelerometerS-link – strain gauge sensor

LabVIEW Real-time Signaling & Processing

CBM Database and real time Monitoring

PDA access Failure Data from anytime and

anywhere

User Interface, Monitoring, & Decision AssistanceWireless Access over the Internet

ARRI CBM Machinery Testbed

Network Configuration Wizard…

On Clicking, Current/default settings for that node appear in

the next screen

Real-Time Plots – LabVIEW User DisplayInternet Access

Time-varying DFT using window (using MATLAB FFT)Discrete Fourier Transform-

1

2

3

4

5

6

7

8

050

100150

200250

300350

400450

500

0

500

1000

(sec)

One second buffer DFT of the speech at a refreshing rate of one second

(Hz)

DFT

0

1

2

3

4

5

6

050

100150

200250

300350

400450

500

0

1000

2000

(sec)

0.5 sec buffer DFT at a refreshing rate of 0.25 sec

(Hz)

DFT

0

1

2

3

4

5

6

050

100150

200250

300350

400450

500

0

1000

2000

(sec)


(Hz)

DFT

Intermittentincipient bearingouter race fault

Onset of geartooth wear

Resulting load imbalance

DFT for CBM

Planetary Gear Transmission

McFadden’s Method


UH-60A Blackhawk HelicopterMain Transmission Planetary Carrier Fault Diagnostics


210 215 220 225 230 235 240 245

0.05

0.1

0.15

0.2

0.25

0.3

0.35

Frequency = k * fc (k: integer, fc: carrier rotation freq.)

Am

plitu

de

Sample spectrum at Harmonic 1

Small shift ofone planet (.1 deg)

Healthy system withtolerance of +/- 0.01degrees in planet anglesMedium shift

of one planet(.15 deg)

High shiftof one planet(.3 deg)

Frequency Domain Plot Dr. George Vachtsevanoshttp://icsl.gatech.edu/icsl

Pattern changes in the SIDEBANDS are useful for diagnostics & prognostics

Planetary gear analysis

Time domain - Moments, statistics, correlation, moving averagesFrequency Domain - Discrete Fourier TransformDynamical System Theory

State Estimation- Kalman Filter System Identification- Recursive Least Squares (RLS)

Statistical TechniquesRegressionPDF estimation

Decision-Making TechniquesBayesianDempster-ShaferRule-Based & Expert SystemsFuzzy Logic

Neural NetworksClassificationClustering

Signal Processing and Decision-Making

Aircraft Nose Wheel Shimmy• Nose wheel can vibrate during landing• Divergent vibration is more likely when nose gear free play is

high and tire is worn• Two approaches

– Monitor and trend free play before taxi – Monitor and trend vibration on landing

Good Nose Gear

Landing Gear with Possible Divergent Shimmy

Shimmy Vibration Measurement

Force

Measured Free Play


Data Pre-Processing is USUALLY REQUIRED

• Task of massaging raw input data and extracting desired information– noise removal– signal enhancement– removal of artifacts– data format transformation, sampling, digitization, etc.– feature extraction– filtering and data compression

Improving signal-to-noise ratio


Time Domain- Moments, Statistics, Correlation

dxxfxxE pp )()(pth moment of RV x(t) with PDF f(x) is

If the RV is ergodic, then its ensemble averages can be approximated by time averages.

N

k

pkx

N 1

1pth moment of time series xk over time interval [1,N] is given by

first moment is the (sample) mean value

N

kkx

Nx

1

1

second moment is the moment of inertia

N

kkx

N 1

21

N

kkx

1

2

energy

root-mean-square (RMS) value

N

kkx

N 1

21

third moment about the mean is the skew – contains symmetry information

N

kk xx

N 1

33 )(1

kurtosis is a measure of the size of the sidelobes of a distribution

3)(11

44

N

kk xx

N

A measure of unbalance

A measure of ‘banging’

SECOND ORDER STATISTICSCorrelation, Covariance, Convolution

N

knkkx xx

NnR

1

1)((auto)correlation

N

knkkx xxxx

NnP

1

))((1)((auto)covariance

N

knkkxy yx

NnR

1

1)(Cross-correlation of two series

N

knkkxy yyxx

NnP

1

))((1)(Cross-covariance

1

0)(*

N

kknk yxnyxdiscrete-time convolution for N point sequences

Needed for Confidence Limits

Statistical Tools for Estimating the PDF

.

..

. ....

. .....

... ..

....

.............

...... .. . . . ...... .

.. .

.

.

. ..

Sample of legacy statistical fault dataVibration magnitudeD

rive

train

gea

r too

th w

ear

failure

. . ....

...

. . . ...... ..

. ..

... . .

....

... . . . ...... .

.. .

.

... . ..

....

.. . . ...... .

..

..

Consistent estimator for the joint PDF is

2

2

1212/)1( 2

)(exp2

)()(exp1)2(

1),(

iN

i

iTi

nn

zzxxxxN

zxP

dzzxp

dzzxzpxzE

),(

),(]/[

Conditional expected value formula

yields estimate for x given z

N

i

iTi

N

i

iTii

xxxx

xxxxzxzE

12

12

2)()(exp

2)()(exp

]/[

Given statistical data

This also gives error covariance or Confidence measure

(xi,yi)

Parzen estimator for PDF

= sum of Gaussians

Parzen pdf Estimator- Example

Legacy Historcial Failure data Gaussian pdf centered at data points

Sum of Gaussians pdf SoG pdf contours

Discrete Fourier Transform (DFT)

N

n

NnkjenxkX1

/)1)(1(2)()( Given time series x(n), DFT is ; k= 1,2,…N

DFT is periodic with period N

)1(2 k

Nw Scale the frequency axis -

Time-varying DFT using window (using MATLAB FFT)Discrete Fourier Transform-

1

2

3

4

5

6

7

8

050

100150

200250

300350

400450

500

0

500

1000

(sec)

One second buffer DFT of the speech at a refreshing rate of one second

(Hz)

DFT

0

1

2

3

4

5

6

050

100150

200250

300350

400450

500

0

1000

2000

(sec)


(Hz)

DFT

0

1

2

3

4

5

6

050

100150

200250

300350

400450

500

0

1000

2000

(sec)


(Hz)

DFT

Intermittentincipient bearingouter race fault

Onset of geartooth wear

Resulting load imbalance

DFT for CBM

Planetary Gear Transmission

McFadden’s Method


UH-60A Blackhawk HelicopterMain Transmission Planetary Carrier Fault Diagnostics


210 215 220 225 230 235 240 245

0.05

0.1

0.15

0.2

0.25

0.3

0.35

Frequency = k * fc (k: integer, fc: carrier rotation freq.)

Am

plitu

de

Sample spectrum at Harmonic 1

Small shift ofone planet (.1 deg)

Healthy system withtolerance of +/- 0.01degrees in planet anglesMedium shift

of one planet(.15 deg)

High shiftof one planet(.3 deg)

Frequency Domain Plot Dr. George Vachtsevanoshttp://icsl.gatech.edu/icsl

Pattern changes in the SIDEBANDS are useful for diagnostics & prognostics

Planetary gear analysis

Wireless Aircraft Health Monitoring actual Navy application

ProposedSensor Locations

Marine H53 Helicopter (Pax River)


Kalman Filter – for noise removal, signal enhancement, trend prediction

( )

( )

( )

1

1

11

ˆ ˆ ˆ ,

,

.

k k k k k k

T Tk k k

T T T Tk k k k k

x Ax Bu AK z Hx

K P H HP H R

P A P P H HP H R HP A GQG

- - -+

-- -

-- - - - -+

= + + -

= +

é ù= - + +ê úë û

Kalman Filter (Discrete Time)

Estimate update

Kalman gain

Covariance update

( ) 1.T T T T TP APA APH HPH R HPA GQG

-= - + +

Steady-State KF

Time-Varying KF

kkkk GwBuAxx 1

kkk vHxz

Stochastic Dynamical System

Dynamics plus process noise

Sensor outputs plus measurement noise

Dynamics A, B, G, H are known. Internal state xk is unknown

Find the full state xk given only a few sensor measurements zk

KF Also Gives Error Covariance- a measure of accuracy and

confidence in the estimate

0 1 2 3

errorcovariancea priorierror covariance

a posteriorierror covariance P0 P1 P2 P3

time

P1 P2 P3

Error covariance update timing diagram

industrial processes - uta talks 2017/diag prog 15.pdfchina education ministry project 111...

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