Computational framework for real-time diagnostics and prognostics of aircraft actuation systems

Advances in the manufacturing industry have led to modern approaches such as Industry 4.0, Cyber-Physical Systems, Smart Manufacturing (SM) and Digital Twins. The traditional manufacturing architecture that consisted of hierarchical layers has evolved into a hierarchy-free network in which all the areas of a manufacturing enterprise are interconnected. The field devices on the shop floor generate large amounts of data that can be useful for maintenance planning. Prognostics and Health Management (PHM) approaches use this data and help us in fault detection and Remaining Useful Life (RUL) estimation. Although there is a significant amount of research primarily focused on tool wear prediction and Condition-Based Monitoring (CBM), there is not much importance given to the multiple facets of PHM. This paper conducts a review of PHM approaches, the current research trends and proposes a three-phased interoperable framework to implement Smart Prognostics and Health Management (SPHM). The uniqueness of SPHM lies in its framework, which makes it applicable to any manufacturing operation across the industry. The framework consists of three phases: Phase 1 consists of the shopfloor setup and data acquisition steps, Phase 2 describes steps to prepare and analyze the data and Phase 3 consists of modeling, predictions and deployment. The first two phases of SPHM are addressed in detail and an overview is provided for the third phase, which is a part of ongoing research. As a use-case, the first two phases of the SPHM framework are applied to data from a milling machine operation.

Prognostics and health management (PHM) is one of the research hotspots in reliability, where remaining useful life (RUL) estimation is a typical application scenario. In this article, a feature learning method based on dynamic Bayesian networks (DBNs) is proposed to improve the RUL estimation accuracy of the regression models. The best feature set is obtained with the conditional dependencies represented by the DBN structure. A local modeling method is applied here to reduce the computation for high-order DBN construction. The strength of the connections between variables together with a contribution index of variables in the DBN structure are defined to represent the feature importance of the variables. Feature transfer is carried out with feature importance under different operating conditions for a further improvement. Nonlinear regression models such as support vector regression (SVR) and Gaussian mixture regression (GMR) are built based on the learned features and used to estimate the RUL. The turbofan engine dataset C-MAPSS is used to validate the effectiveness of the proposed method. Compared with other recent RUL estimation models, the proposed method has a faster modeling speed and higher prediction accuracy.

Advanced control of large-scale wind turbines: Structural load reduction and lifetime control

Remaining useful life (RUL) estimation is considered as one of the most central points in the prognostics and health management (PHM). The present paper describes a nonlinear hybrid ABC–MARS-based model for the prediction of the remaining useful life of aircraft engines. Indeed, it is well-known that an accurate RUL estimation allows failure prevention in a more controllable way so that the effective maintenance can be carried out in appropriate time to correct impending faults. The proposed hybrid model combines multivariate adaptive regression splines (MARS), which have been successfully adopted for regression problems, with the artificial bee colony (ABC) technique. This optimization technique involves parameter setting in the MARS training procedure, which significantly influences the regression accuracy. However, its use in reliability applications has not yet been widely explored. Bearing this in mind, remaining useful life values have been predicted here by using the hybrid ABC–MARS-based model from the remaining measured parameters (input variables) for aircraft engines with success. A correlation coefficient equal to 0.92 was obtained when this hybrid ABC–MARS-based model was applied to experimental data. The agreement of this model with experimental data confirmed its good performance. The main advantage of this predictive model is that it does not require information about the previous operation states of the aircraft engine.

고장 예지 및 건전성 관리 기술(Prognostics and Health Management; PHM)은 시스템의 현재 상태를 진단하고 향후 발생 가능한 고장 시점을 신뢰성 있게 예지하는 기술로써 유지 보수 비용의 절감 및 시스템의 안정성 향상을 꾀하고자 하는 다양한 산업분야에서 활발하게 이용되고 있다. 스마트 그리드의 에너지 저장장치, 전기차, 스마트폰, 항공우주산업 등 광범위한 사용처에서 중요한 에너지원으로 사용되고 있는 배터리 또한 성능 저하 및 폭발의 위험성으로부터 자유로울 수 없기 때문에 이러한 고장 예지 및 건전성 관리 기술이 반드시 적용되어야 할 어플리케이션이다. 본 논문에서는 PHM의 기본적인 개념을 소개함과 동시에 배터리의 잔존 유효 수명(Remaining Useful Life; RUL)을 예측하는 각종 알고리즘 및 성능 평가 지표 서술에 초점을 맞추도록 한다. 더불어 배터리의 기능적 동작 원리 및 전기화학 기반의 모델링에 대한 설명을 통해 향후 잠재적인 가능성을 지닌 배터리의 전반적인 특성에 대한 깊은 이해 및 응용 기술에 대한 통찰력을 제시하고자 한다. Prognostics and health management(PHM) is actively utilized by industry as an essential technology focusing on accurately monitoring the health state of a system and predicting the remaining useful life(RUL). An effective PHM is expected to reduce maintenance costs as well as improve safety of system by preventing failure in advance. With these advantages, PHM can be applied to the battery system which is a core element to provide electricity for devices with mobility, since battery faults could lead to operational downtime, performance degradation, and even catastrophic loss of human life by unexpected explosion due to non-linear characteristics of battery. In this paper we mainly review a recent progress on various models for predicting RUL of battery with high accuracy satisfying the given confidence interval level. Moreover, performance evaluation metrics for battery prognostics are presented in detail to show the strength of these metrics compared to the traditional ones used in the existing forecasting applications.

Prognostics, in other words, remaining useful life (RUL) estimation is a core task of prognostics and health management (PHM). Reliable RUL predictions can reduce maintenance costs, improve production efficiency, and avoid unexpected downtime. Lots of models for RUL predictions have been proposed; however, noise and the nonlinear nature of degradation phenomena often leads to poor prognostics results, and the acquired engineered system data are usually subject to a high level of uncertainty. This makes the RUL estimation models less than satisfactory. Accurate RUL estimation and prediction not only rely on an accurate model but also depend on the adjustments of model parameters to track the variation. In this paper, an ensemble model combining the health index synthesis (HIS) approach and improved particle filtering (PF) is introduced. HIS approach was used to obtain the synthesized health index (SHI) for an engineered system with multiple sensors, which indicated the system's degradation model, while the improved PF approach was used to adjust the parameters of the degradation model obtained from the HIS approach and optimized the RUL estimation results. The performance of the prognostics approach introduced in this paper was demonstrated by using turbofan engine degradation data sets, which was supplied by NASA Ames, and results were compared with several usually used methods.

In the operations and maintenance (O&M) management of industrial robots, data-driven methods often lack interpretability and decision-making support. To address these limitations, this paper proposes a data- and knowledge-co-driven framework for Prognostics and Health Management (PHM). The framework is designed to accommodate the complex structure and multi-source data characteristics of industrial robots, with a focus on three core tasks: condition monitoring, fault diagnosis, and remaining useful life (RUL) prediction. For each task, appropriate deep learning models are selected to fit the PHM architecture. On the knowledge-driven side, a knowledge extraction process based on pre-trained language models is employed. On the knowledge-driven side, a pre-trained language model is employed for knowledge extraction. By integrating equipment structure with fault evolution logic, a knowledge graph is constructed to support the integration and semantic reasoning of operation and maintenance knowledge. This results in a PHM management framework driven by both data and knowledge, providing a feasible design concept and implementation pathway for future research and practical applications.

Prognostics and health management (PHM) is an important part of ensuring reliable operations of complex safety- critical systems. System-level remaining useful life (RUL) estimation is a much more complex problem than making estimations at the component level, and system-level RUL methodologies remain sparse in the literature. Model-based approaches have traditionally worked in the past for components such as capacitors, MOSFETs, batteries, or hard-drives (to name a few examples), but developing high fidelity dynamics models of cyber physical systems that can be used to study the effects of multiple degrading components in the system remains a challenging task. Some initial work on model-based System RUL predictions was demonstrated in Khorasgani, et al [1], but, to generalize the system-level prognostics problem, we have to resort to pure data driven and hybrid approaches. In this work, we propose an end-to-end data- driven framework for developing deep learning models to predict remaining useful life of cyber physical systems operating under unknown faulty conditions. The raw data is organized with a data schema that improves the model development process anddown stream data analysis tasks. Due to the unknown faulty conditions, the raw sensor data is transformed into signals that expose the underlying degradation processes, which are then used for model development. Bayesian Optimization is used to tune the model parameters prior to training and validation. We show that this approach results in accurate predictions within 3 cycles to end of life (EOL). We demonstrate the effectiveness of our approach by applying it to the N-CMAPSS turbofan engine dataset recently released by NASA, which includes high fidelity degradation modeling, real world operating conditions, and a large set of fault operating modes.

Remaining useful life with self-attention assisted physics-informed neural network

In the era of smart manufacturing and advanced industrial systems, the high degree of integration and intelligence of equipment demands higher reliability and safety from systems. Existing methods often rely on historical data for Remaining Useful Life (RUL) prediction to achieve Prognostic and Health Management (PHM). However, the internal units of complex equipment exhibit significant spatial correlation and temporal diversity, making PHM for complex equipment a multidimensional challenge involving both temporal and spatial information, thereby severely limits the effectiveness of RUL prediction for complex systems. Addressing these challenges, this study introduces a multi-scale spatiotemporal attention network with adaptive relationship mining, specifically designed for the remaining useful life (RUL) prediction of such equipment. The core of the proposed method lies in the multi-scale feature perception module, which adeptly extracts varied scale features from multidimensional sensor data. Following this, an innovative adaptive relationship mining module is integrated to uncover multi-order coupling relationships between diverse sensors, enhancing the model’s predictive accuracy. Furthermore, a spatiotemporal attention module is employed to discern and emphasize crucial spatiotemporal correlations. To validate the effectiveness and superiority of the proposed method, the Commercial Modular Aero-propulsion System Simulation (C-MAPSS) dataset is employed for comprehensive performance evaluation, the IEEE 2012 PHM bearing dataset is also adopted to demonstrate the generalization and robustness of the proposed method. The results not only show a notable improvement over existing methods but also offer a more intuitive understanding through visual representations, marking a significant stride in enhancing the safety and efficiency of complex systems.

Predicting the Remaining Useful Life (RUL) of turbofan engines can prevent air disasters caused by component degradation. It is an important procedure in prognostics and health management (PHM). Therefore, a deep learning-based RUL prediction approach is proposed. The CMAPSS benchmark dataset is used to determine the RUL of aviation engines, focusing specifically on the FD001 and FD003 sub-datasets.In this study, we propose a CAELSTM (Convolutional Autoencoder and Attention-based LSTM) hybrid model for RUL prediction. First, the sub-datasets are preprocessed, and a piecewise linear degradation model is applied. The proposed model utilizes an autoencoder followed by an LSTM layer with an attention mechanism, which focuses on the most relevant components of the sequences. A fully connected layer of the convolutional neural network is used to further process the important features. Finally, the proposed model is evaluated and compared with other approaches. The results show that the model surpasses state-of-the-art methods, achieving RMSE values of 14.44 and 13.40 for FD001 and FD003, respectively. Other evaluation criteria, such as MAE and scoring, were also used, with MAE achieving values of 10.49 and 10.68 for FD001 and FD003, respectively. The scoring achieved values of 282.38 and 264.47 for the same sub-datasets. These results highlight the model's promise for improving prognostics and health management (PHM) systems, offering a dependable tool for predictive maintenance in aerospace and related fields. They also demonstrate the effectiveness and superiority of the model in enhancing aviation safety.

Aluminum electrolytic capacitor is one of the key components that restrict the life of DC-DC converter. Studying its deterioration analysis has advanced to realizing the prognostics and health management (PHM) technology of DC-DC converter. The main deterioration modes of aluminum electrolytic capacitor include the capacitance decrease and the equivalent series resistance (ESR) increases. These cause the ripple voltage to increase and eventually lead to the DC-DC converter failure. Some parameters of DC-DC converter (such as the ripple voltage, the ripple current, etc.) are selected as the feature signals of the aluminum electrolytic capacitor deterioration. By monitoring the changes of the feature signals, the aluminum electrolytic capacitor deterioration degree can be measured indirectly. Through theoretical analysis, this paper proposed a new idea to predict the remaining useful life (RUL) of DC-DC converter, that is, establishing the curve of the ripple voltage as the aluminum electrolytic capacitor deterioration and setting a warning point in the curve. When the change rate of the ripple voltage reached the warning point, the life of the DC-DC converter will come to an end. So, the RUL of the DC-DC converter can be predicted. In this paper, the buck converter is verified by simulation and physical experiments amid good agreements with the theory. Key words: Aluminum electrolytic capacitor, DC-DC converter, deterioration, capacitance, equivalent series resistance (ESR), ripple voltage, remaining useful life (RUL), prognostics and health management (PHM).

Degradation data-driven approach for remaining useful life estimation

Remaining useful life (RUL) estimation is the key of prognostics and health management (PHM) technology and is an effective way to ensure the safe and reliable operation of equipment. Aiming at the lack of historical data and prior information for the newly developed small-sample systems, an adaptive RUL estimation method based on the expectation maximization (EM) algorithm is proposed with three-source variability. First, a degradation model based on a Wiener process is established to incorporate three-source variability and dynamic sampling interval, and the analytical solution of RUL distribution is derived in the sense of the first hitting time. Second, an adaptive parameter estimation method based on the EM algorithm is proposed to update the model parameters by using the condition monitoring (CM) data from one working system running up to the current moment. Finally, a practical example of a gyroscope in an inertial navigation system is provided to substantiate the effectiveness and superiority of the proposed method. The results indicate that the proposed method can efficiently improve the accuracy of the RUL estimation.

Health status assessment and remaining useful life prediction of aero-engine based on BiGRU and MMoE