r. i. tu darmstadt ifac safeprocess: - history, status, experiences - rolf isermann ifac...
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R. I. TU Darmstadt
IFAC SAFEPROCESS: - History, Status, Experiences -
Rolf Isermann
Darmstadt University of TechnologyInstitute of Automatic Control
Darmstadt, Germany
Opening Session 7th IFAC Symposium SAFEPROCESS, Barcelona, 1st July 2009
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R. I. TU Darmstadt
IFAC SAFEPROCESS
1. History
2. Status
3. Experiences
4. Outlook
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R. I. TU Darmstadt
O On the history of IFAC SAFEPROCESS
– Until 1990: fault detection and supervision treated in special sessions of symposia and congresses
– 1989: Application for a Conference SAFEPROCESS by German NMO accepted
– 1st Symposium SAFEPROCESS in Baden-Baden, 10-13 Sep. 1991– Title SAFEPROCESS was selected as abbreviation of the field (similar as
IFAC/IFIP Workshops SAFECOMP for computer systems)– 1991: Steering committee founded in Baden-Baden to support continuity– 1993: IFAC Technical Committee SAFEPROCESS accepted within the
Application Committee of the IFAC Technical Board– 1993: Technical Board accepts IFAC SAFEPROCESS on the Masterplan
for Symposia– 1994: 2nd IFAC Symposium SAFEPROCESS in Espoo, Finland:
→ A new Symposium series got started
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R. I. TU Darmstadt
Preface Proceeedings1 st IFAC-SAFEPROCESS1991
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R. I. TU Darmstadt
Preface of Preprints 1st IFAC SAFEPROCESS 1991 Baden-Baden
RI 1991
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R. I. TU Darmstadt
Rolf IsermannBernd Freyermuth
• 137 papers• 287 participants• 55 % from industry
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R. I. TU Darmstadt
Pentti LautalaBjörn WahlströmTuula Ruokonen
• 133 papers• 220 participants
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R. I. TU Darmstadt
Ron J. PattonSteve DaleyJie Chen
• 209 papers• 200 participants
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R. I. TU Darmstadt
Josef BokorAndras M. EdelmayerCsilla Banyasz
• 200 papers• 200 participants
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R. I. TU Darmstadt
Janos GertlerMarcel StaroswieckiN. Eva Wu
• 197 papers• 175 participants
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R. I.TU Darmstadt
Beijing, P.R. China
August 29-September 1 ,2006
6th IFAC Symposium on
Fault Detection, Supervision and Safety of Technical Processes
J. KorbiczD.H. ZhouH.Y. Zhang
258 papers201 partipants
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R. I. TU Darmstadt
Janos GertlerRon Patton
Joseba QuevedoTeresa EscobetVicenc PuigBernardo MorcegoAndreu Quesada
264 papers292 participants (207 professionals 85 students) (26 June 09)
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R. I. TU Darmstadt
IFAC
O IFAC Technical Committee Chemical Process Control:– IFAC Workshops: Fault detection and supervision in the chemical process
industries• 1992: Newark-Delaware, USA• 1995: Newcastle, UK• 1998: Solaize-Lyon, FR• 2001: Cheju, KR
O IFAC Congresses:• 1990 Tallinn: 1 session• 1993: Sydney: 4 sessions• 1996: San Francisco: 9 sessions• 1999: Beijing: • 2002: Barcelona: 13 sessions• 2005: Prague: 11 sessions, • 2008: Seoul: 5 sessions + CC1, CC2
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R. I. TU Darmstadt
IFAC SAFEPROCESS
1. History
2. Status
3. Experiences
4. Outlook
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R. I. TU Darmstadt
O IFAC Technical Committee SAFEPROCESS :
– Planning and organisation of new Symposia• Foundation of International Program Committees• Selection of Guest-Countries• Design and maintenance of TC web page• TC Chairs act for 3 years, can be expanded to another 3 years• 2008: 65 members
– Organisation of Sessions for IFAC Congresses– 1991- 1996: Terminology on fault detection and diagnosis
• Control Engineering Practice 5 (1997), 709-719• http://www.rtm.tu-darmstadt.de/fd_terminology.html
– Technical Committee Chairs:• 1991 – 1996 Rolf Isermann• 1996 - 2002 Ron Patton• 2002 – 2008 Michel Kinnaert / Michelle. Basseville/ Jakob Stoustrup• 2008 - 2011 Jakob Stoustrup / Michel Kinnaert /Michel Verhaegen
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R. I. TU Darmstadt
IFAC SAFEPROCESS
1. History
2. Status
3. Experiences• Methods• Applications
4. Outlook
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R. I. TU Darmstadt
Fault Management
Fault-management actions
Ope-rator
F Fault
Alarm
ChangeOperation
Reconfi-guration
Decision
Hazard Classes
FaultEvaluation
Fault
FaultDiagnosis
Symptoms
FaultDetection
Protection
SignalEvaluation
StopOperation
[W, U] C P[U, X, Y]
FeatureGeneration
Features
Mainte-nance
Repair
Process and Control
Measurements
Con
trol
and
Pro
cess
Lev
el
Supervisionw. FaultDiagnosis
Protec-tion
Monitoring
Sup
ervi
sory
Lev
el
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R. I. TU Darmstadt
limitchecking
signalmodels
used
FAULT- DETECTION METHODS
detection withsingle signals
detection with multiplesignals and models
processmodels
used
multi-variatedata
analysis
trendchecking
spectrumanalysis
fixedthres-hold
change-detectionmethods
correla-tion
Waveletanalysis
adaptivethresh-olds
neuralnetworks
param.estim.
stateob-
servers
stateestim.
parityequa-tions
principalcomponent
analysis
Extract of fault detection methods
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R. I. TU Darmstadt
IFAC SAFEPROCESS
1. History
2. Status
3. Experiences• Methods• Applications
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R. I. TU Darmstadt
Research projects at IAT (33 Doctoral thesis 1981 – 2008, 50 % industry projects):
1. Electrical drivesO DC motors
• With brushes• Electronic commutation
O Inductionmotors• Asynchroneous motors frequency
controlled, with inverters
O Universalmotors
2. ActuatorsO Electrical throttleO Electrical cabine pressure valve
(aircraft ,BLDC)O Pneumatic cylinder- and
membrane actuatorsO Hydraulic Servoaxis
3. PumpsO Centrifugal pumps with DC- and AC-
motorsO Reciprocating pump
(oscillating pump)
4. Plants• Pipeline leak detection and localization
liquids and gases (ethylen)• Heat exchangers (steam/water., heating boilers)
5. Manufacturing• Feeddrive (DC-, Synchron-Mot)• Production center (MAHO MC5)
main drive, feed drives milling, drilling, turning
• Grinding machines• Industrial robot (6 axes)
6. Automobiles
• Suspension, active suspension (ABC)• Hydraulic brake system• Drive dynamic stability, over-, understeering• Fault-tolerant sensor platform
7. Internal combustion engines• Gasoline engines• Diesel engines
8. Fault-tolerant systems• Duplex-Asynchroneous-drivee • Duplex-valve hydraulic servo system
→ Isermann, R.: Fault Diagnosis of Technical Processes, Springer-Verlag, Berlin, 2009/2010
Theoretical and experimental experiences in development of fault diagnososi methods
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R. I. TU Darmstadt
Require-ments
Process-analysis.
- process: - linearizable - nonlinear- operation - stationary - dynamic- signals: - periodic - stochastic
- available measurements- operating conditions- open/closed loop
Selectionfault detectionmethods
- signal model based: - Fourieranalys. - wavelets, …- process model based: - paramet. estim. - parity equations - observers, K.F. .
- adjustment to real process and real signals- modeltypes: - linear - nonlinear - time variant- test signals: - yes: type - no
Simulations
- process modeling: - physical - identification - semi-physical- signal models: - periodic, harmonics - ARMA - disturbances
- test of methods- combination of methods- fault coverage- fault
diagnosis: - isolability - classification - inference meth.
feedbacks for improvements
- kind of faults- number of faults- fault detection coverage- smallest replaceable unit
- fault list: - actuators - process - sensors- fault-sympt. trees- application? - maintenance - fault tolerance
Preco
nd
ition
sR
esults
Development stages for fault detection and diagnosis
- process computer - real time - filtering,….- real operating conditions - real signals- inserting real faults
- adjustment of: - models - filters - tuning parameters- faults: - detecable ? - size ? - diagnosible ?
Experimentswithreal process
- field tests- all operating conditions- reliability ?- maintainability ?- customer acceptance ?
FinalSoftw/hardw.realization.
- tests with other processes- robustness issues (process tolerances)
compari-son
Ready
for use
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R. I. TU Darmstadt
Outlook: Technical driving forces for SAFEPROCESS ?1. Asset management → improvement of availability and economics
• Maintenance on demand• Forecast of maintenance• Estimation of availability• Life cycle optimization
2. Fault tolerant systems → improvement of safety (and availability)• Fault tolerant sensors• Fault tolerant actuators and drives• Fault tolerant processes• Fault tolerant control• Until now: for safety relevant systems only
3. Development tools → improvement of applicability• for fault detection and diagnosis methods• user friendly, with best practice approaches• Integration of analytical + heuristic information on process behavior• Combined diagnosis for continuous + discrete event processes
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R. I. TU Darmstadt
O Important issues for successful detection & diagnosis methods:
1. Physical/technical understanding of fault propagation to measured signals
2. Physical & experimental based modeling of actuators, processes and sensors
3. Adjustment of suitable detection methods to real faults
4. Experimental and engineering skill & validation of methods
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R. I. TU Darmstadt
Fault diagnosis + fault management: wide technical applications