Data-driven Diagnostics and Prognostics for Complex Systems


Book Description

Recent advances in artificial intelligence or machine learning have the potential to significantly improve the effectiveness and efficiency of diagnostic and prognostic techniques. The objective of this research is to develop novel data-driven predictive models with machine learning and deep learning algorithms that allow one to model the degradation, detect the faults, as well as predict the remaining useful life (RUL) of complex systems, including bearings, gearboxes, and Lithium-ion (Li-ion) batteries. First, an enhanced ensemble learning algorithm is developed to improve the accuracy of RUL prediction by selecting diverse base learners and features at different degradation stages. The proposed method with increased diversity in base learners and features was demonstrated to be more accurate than other reported algorithms. Second, a convolutional long short-term memory (Conv-LSTM) approach is introduced to accurately classify the type, position, and direction of gear faults under different operating conditions by extracting spatiotemporal features from multiple sensors. The proposed method achieved 95% classification accuracy of fault type and 80% classification accuracy of fault location. Third, a deep learning method that combines convolutional neural networks (CNN) and bi-directional long short-term memory (BiLSTM) is developed to predict the discharge capacity and the end-of-discharge (EOD) of Li-ion batteries. The results show that by considering the discharge capacity estimated by CNN, the MAPE of EOD prediction using BiLSTM decreased from 8.52% to 3.21%. Fourth, a physics-informed machine learning method that combines the calendar and cycle aging (CCA) model and a LSTM model is developed to predict battery degradation behavior and RUL under different working conditions. The results show that the proposed method can predict the RUL of batteries accurately (10% in term of MAPE).




Data-Driven Design of Fault Diagnosis Systems


Book Description

In many industrial applications early detection and diagnosis of abnormal behavior of the plant is of great importance. During the last decades, the complexity of process plants has been drastically increased, which imposes great challenges in development of model-based monitoring approaches and it sometimes becomes unrealistic for modern large-scale processes. The main objective of Adel Haghani Abandan Sari is to study efficient fault diagnosis techniques for complex industrial systems using process historical data and considering the nonlinear behavior of the process. To this end, different methods are presented to solve the fault diagnosis problem based on the overall behavior of the process and its dynamics. Moreover, a novel technique is proposed for fault isolation and determination of the root-cause of the faults in the system, based on the fault impacts on the process measurements.




Big Data-Driven Intelligent Fault Diagnosis and Prognosis for Mechanical Systems


Book Description

This book presents systematic overviews and bright insights into big data-driven intelligent fault diagnosis and prognosis for mechanical systems. The recent research results on deep transfer learning-based fault diagnosis, data-model fusion remaining useful life (RUL) prediction, etc., are focused on in the book. The contents are valuable and interesting to attract academic researchers, practitioners, and students in the field of prognostics and health management (PHM). Essential guidelines are provided for readers to understand, explore, and implement the presented methodologies, which promote further development of PHM in the big data era. Features: Addresses the critical challenges in the field of PHM at present Presents both fundamental and cutting-edge research theories on intelligent fault diagnosis and prognosis Provides abundant experimental validations and engineering cases of the presented methodologies




Data-driven Prognosis and Diagnosis of Event Occurrences with Applications in Manufacturing and Healthcare Systems


Book Description

Information technology revolution is turning modern engineering systems into smart and connected systems and such systems have become increasingly available in practice. Due to the advances in implementation of smart and connected systems, we now have massive data with rich condition monitoring signals of in-situ systems and detailed records of critical events. This unprecedented data availability realized by the smart and connected systems provides significant opportunities for sophisticated data-driven prognosis and diagnosis for the underlying health status of a system in various fields. Successful prognosis and diagnosis can prevent catastrophic consequences in advance and provide meaningful information about the underlying health status of a system. However, at the same time, it also creates new challenges for research in data analytics as to how this vast and complex data could be utilized to retrieve accurate prognosis and meaningful diagnosis. Many existing techniques fall short of addressing this issue because most of them are for the cases where the data were collected in a well-controlled experimental setting. The critical event records and condition monitoring data obtained from the complex smart and connected systems often involve many factors that are uncontrollable and inevitably exhibit severe heterogeneity. This thesis addresses multiple challenges for prognosis and diagnosis based on such data by establishing a series of data-driven methodologies. (a) To build a joint model framework for both time-to-failure data and condition monitoring signals by integrating Cox regression and mixed-effects model. (b) To extend the joint model framework to address various issues in the prognosis based on the monitoring data. (c) Establishing a joint prognostic model for recurrent events by hierarchically integrating logistic regression and mixed-effects models. (d) To establish a diagnostic model based on recurrent event data using correlated Gamma-based hidden Markov model. The proposed methods can be applied to a broad range of data analytics applications, and the emerging challenges in monitoring data obtained from smart and connected systems can be effectively addressed.




Prognostics


Book Description

Prognostics is the science of making predictions of engineering systems. It is part of a suite of techniques that determine whether a system is behaving within nominal operational performance and - if it does not - that determine what is wrong and how long it will take until the system no longer fulfills certain functional requirements. This book presents the latest developments and research findings on the topic of prognostics by the Prognostics Center of Excellence at NASA Ames Research Center. The book is intended to provide a practitioner with an understanding of the foundational concepts as well as practical tools to perform prognostics and health management on different types of engineering systems and in particular to predict remaining useful life.







Diagnosis and Fault-tolerant Control 1


Book Description

This book presents recent advances in fault diagnosis strategies for complex dynamic systems. Its impetus derives from the need for an overview of the challenges of the fault diagnosis technique, especially for those demanding systems that require reliability, availability, maintainability and safety to ensure efficient operations. Moreover, the need for a high degree of tolerance with respect to possible faults represents a further key point, primarily for complex systems, as modeling and control are inherently challenging, and maintenance is both expensive and safety-critical. Diagnosis and Fault-tolerant Control 1 also presents and compares different diagnosis schemes using established case studies that are widely used in related literature. The main features of this book regard the analysis, design and implementation of proper solutions for the problems of fault diagnosis in safety critical systems. The design of the considered solutions involves robust data-driven, model-based approaches.




Data-driven Prognosis and Diagnosis of Event Occurrences with Applications in Manufacturing and Healthcare Systems


Book Description

Information technology revolution is turning modern engineering systems into smart and connected systems and such systems have become increasingly available in practice. Due to the advances in implementation of smart and connected systems, we now have massive data with rich condition monitoring signals of in-situ systems and detailed records of critical events. This unprecedented data availability realized by the smart and connected systems provides significant opportunities for sophisticated data-driven prognosis and diagnosis for the underlying health status of a system in various fields. Successful prognosis and diagnosis can prevent catastrophic consequences in advance and provide meaningful information about the underlying health status of a system. However, at the same time, it also creates new challenges for research in data analytics as to how this vast and complex data could be utilized to retrieve accurate prognosis and meaningful diagnosis. Many existing techniques fall short of addressing this issue because most of them are for the cases where the data were collected in a well-controlled experimental setting. The critical event records and condition monitoring data obtained from the complex smart and connected systems often involve many factors that are uncontrollable and inevitably exhibit severe heterogeneity. This thesis addresses multiple challenges for prognosis and diagnosis based on such data by establishing a series of data-driven methodologies. (a) To build a joint model framework for both time-to-failure data and condition monitoring signals by integrating Cox regression and mixed-effects model. (b) To extend the joint model framework to address various issues in the prognosis based on the monitoring data. (c) Establishing a joint prognostic model for recurrent events by hierarchically integrating logistic regression and mixed-effects models. (d) To establish a diagnostic model based on recurrent event data using correlated Gamma-based hidden Markov model. The proposed methods can be applied to a broad range of data analytics applications, and the emerging challenges in monitoring data obtained from smart and connected systems can be effectively addressed.







Data-driven Approaches for Condition Monitoring and Predictive Analytics


Book Description

The rapid development of sensing and communication technologies has enabled an unprecedented opportunity for condition monitoring, making multiple data streams a commonplace to simultaneously monitor the health status of an operating unit. Such a big data environment poses essential challenges in determining (i) which data streams to use; and (ii) how to fuse/combine those multiple and relevant data streams for better failure diagnosis and prognostics as these multiple data streams are often correlated and each data stream may only contain partial information about the degraded unit. However, it is often hard to physically interpret the dependencies and relations between these data streams due to the complexity of the system. Given the massive amount of data have become available, nowadays many research companies are looking for effective tools to improve failure monitoring and predictive capabilities. As a consequence, my research focuses on developing effective data-driven methodologies to better monitor and infer the condition of an operating unit in real time. Such inference would be very useful for profitable managerial decision-making such as condition-based maintenance scheduling, work in progress distribution, shipment scheduling, and customer satisfaction. This thesis contributes to the field of System Informatics and Data Analytics (SIDA) by developing systematic data-driven methodologies for better condition monitoring and prognostic analysis in complex systems. These developed methodologies enable (i) real time modeling and characterization of the health status of a system, (ii) predicting future measurements, trends and behaviors of the system, and (iii) further diagnosing the reasons for degradation and failure of the system. This research combines advanced statistical methods, data analytics tools, engineering knowledge, and decision science and operations research. The research is highly applicable in many applications such as health care, manufacturing, after sales and services.