Detection and Characterization of Multiple Discontinuities in Cables with Time-Domain Reflectometry and Convolutional Neural Networks

In this paper, a convolutional neural network for the detection and characterization of impedance discontinuity points in cables is presented. The neural network analyzes time-domain reflectometry signals and produces a set of estimated discontinuity points, each of them characterized by a class describing the type of discontinuity, a position, and a value quantifying the entity of the impedance discontinuity. The neural network was trained using a great number of simulated signals, obtained with a transmission line simulator. The transmission line model used in simulations was calibrated using data obtained from stepped-frequency waveform reflectometry measurements, following a novel procedure presented in the paper. After the training process, the neural network model was tested on both simulated signals and measured signals, and its detection and accuracy performances were assessed. In experimental tests, where the discontinuity points were capacitive faults, the proposed method was able to correctly identify 100% of the discontinuity points, and to estimate their position and entity with a root-mean-squared error of 13 cm and 14 pF, respectively.

Actuator Fault Detection for Unmanned Ground Vehicles Considering Friction Coefficients

This paper proposes an actuator fault detection method for unmanned ground vehicle (UGV) dynamics with four mecanum wheels. The actuator fault detection method is based on unknown input observers for linear parameter varying systems. The technical novelty of current work compared to similar work in the literature is that wheel frictions are directly taken into account in the dynamics of UGV, and unknown input observers are developed accordingly. Including the wheel friction, the vehicle dynamics are in the form of linear parameter varying systems. Friction estimation is also discussed in this work, and the effect of friction mismatch was quantitatively investigated by simulations. The effectiveness of proposed method was evaluated under various operation scenarios of the UGV.

A Sequential Inspection Procedure for Fault Detection in Multistage Manufacturing Processes

Fault diagnosis in multistage manufacturing processes (MMPs) is a challenging task where most of the research presented in the literature considers a predefined inspection scheme to identify the sources of variation and make the process diagnosable. In this paper, a sequential inspection procedure to detect the process fault based on a sequential testing algorithm and a minimum monitoring system is proposed. After the monitoring system detects that the process is out of statistical control, the features to be inspected (end of line or in process measurements) are defined sequentially according to the expected information gain of each potential inspection measurement. A case study is analyzed to prove the benefits of this approach with respect to a predefined inspection scheme and a randomized sequential inspection considering both the use and non-use of fault probabilities from historical maintenance data.

Non-Singleton Type-3 Fuzzy Approach for Flowmeter Fault Detection: Experimental Study in a Gas Industry

The main contribution of this paper is to develop a new flowmeter fault detection approach based on optimized non-singleton type-3 (NT3) fuzzy logic systems (FLSs). The introduced method is implemented on an experimental gas industry plant. The system is modeled by NT3FLSs, and the faults are detected by comparison of measured end estimated signals. In this scheme, the detecting performance depends on the estimation and modeling performance. The suggested NT3FLS is used because of the existence of a high level of measurement errors and uncertainties in this problem. The designed NT3FLS with uncertain footprint-of-uncertainty (FOU), fuzzy secondary memberships and adaptive non-singleton fuzzification results in a powerful tool for modeling signals immersed in noise and error. The level of non-singleton fuzzification and membership parameters are tuned by maximum correntropy (MC) unscented Kalman filter (KF), and the rule parameters are learned by correntropy KF (CKF) with fuzzy kernel size. The suggested learning algorithms can handle the non-Gaussian noises that are common in industrial applications. The various types of flowmeters are investigated, and the effect of common faults are examined. It is shown that the suggested approach can detect the various faults with good accuracy in comparison with conventional approaches.

Fault Detection in the MSW Incineration Process Using Stochastic Configuration Networks and Case-Based Reasoning

Fault detection in the waste incineration process depends on high-temperature image observation and the experience of field maintenance personnel, which is inefficient and can easily cause misjudgment of the fault. In this paper, a fault detection method is proposed by combining stochastic configuration networks (SCNs) and case-based reasoning (CBR). First, a learning pseudo metric method based on SCNs (SCN-LPM) is proposed by training SCN learning models using a training sample set and defined pseudo-metric criteria. Then, the SCN-LPM method is used for the case retrieval stage in CBR to construct the fault detection model based on SCN-CBR, and the structure, algorithmic implementation, and algorithmic steps are given. Finally, the performance is tested using historical data of the MSW incineration process, and the proposed method is compared with typical classification methods, such as a Back Propagation (BP) neural network, a support vector machine, and so on. The results show that this method can effectively improve the accuracy of fault detection and reduce the time complexity of the task and maintain a certain application value.

Real-Time Fault Detection and Diagnosis of CaCO3 Reactive Crystallization Process by Electrical Resistance Tomography Measurements

In the present research work, an electrical resistance tomography (ERT) system is utilized as a means for real-time fault detection and diagnosis (FDD) during a reactive crystallization process. The calcium carbonate crystallization is part of the carbon capture and utilization scheme where process monitoring and malfunction diagnostics strategies are presented. The graphical logic representation of the fault tree analysis methodology is used to develop the system failure states. The measurement consistency due to the use of a single electrode from a set of ERT electrodes for malfunction identification is experimentally and quantitatively investigated based on the sensor sensitivity and standard deviation criteria. Electrical current measurements are employed to develop a LabVIEW-based process automation program by using the process-specific knowledge and historical process data. Averaged electrical current is correlated to the mechanical failure of the stirrer through standard deviation evaluation, and slopes of the measured data are used to monitor the pump and concentrations status. The performance of the implemented methodology for detecting the induced faults and abnormalities is tested at different operating conditions, and a basic signal-based alarming technique is developed.

A Sensor Fault Detection Scheme as a Functional Safety Feature for DC-DC Converters

DC-DC converters are widely used in a large number of power conversion applications. As in many other systems, they are designed to automatically prevent dangerous failures or control them when they arise; this is called functional safety. Therefore, random hardware failures such as sensor faults have to be detected and handled properly. This proper handling means achieving or maintaining a safe state according to ISO 26262. However, to achieve or maintain a safe state, a fault has to be detected first. Sensor faults within DC-DC converters are generally detected with hardware-redundant sensors, despite all their drawbacks. Within this article, this redundancy is addressed using observer-based techniques utilizing Extended Kalman Filters (EKFs). Moreover, the paper proposes a fault detection and isolation scheme to guarantee functional safety. For this, a cross-EKF structure is implemented to work in cross-parallel to the real sensors and to replace the sensors in case of a fault. This ensures the continuity of the service in case of sensor faults. This idea is based on the concept of the virtual sensor which replaces the sensor in case of fault. Moreover, the concept of the virtual sensor is broader. In fact, if a system is observable, the observer offers a better performance than the sensor. In this context, this paper gives a contribution in this area. The effectiveness of this approach is tested with measurements on a buck converter prototype.

A Cost-Effective CNN-LSTM-Based Solution for Predicting Faulty Remote Water Meter Reading Devices in AMI Systems

Automatic meter infrastructure (AMI) systems using remote metering are being widely used to utilize water resources efficiently and minimize non-revenue water. We propose a convolutional neural network-long short-term memory network (CNN-LSTM)-based solution that can predict faulty remote water meter reading (RWMR) devices by analyzing approximately 2,850,000 AMI data collected from 2762 customers over 360 days in a small-sized city in South Korea. The AMI data used in this study is a challenging, highly unbalanced real-world dataset with limited features. First, we perform extensive preprocessing steps and extract meaningful features for handling this challenging dataset with limited features. Next, we select important features that have a higher influence on the classifier using a recursive feature elimination method. Finally, we apply the CNN-LSTM model for predicting faulty RWMR devices. We also propose an efficient training method for ML models to learn the unbalanced real-world AMI dataset. A cost-effective threshold for evaluating the performance of ML models is proposed by considering the mispredictions of ML models as well as the cost. Our experimental results show that an F-measure of 0.82 and MCC of 0.83 are obtained when the CNN-LSTM model is used for prediction.

Fault Detection of Wind Turbine Electric Pitch System Based on IGWO-ERF

It is difficult to optimize the fault model parameters when Extreme Random Forest is used to detect the electric pitch system fault model of the double-fed wind turbine generator set. Therefore, Extreme Random Forest which was optimized by improved grey wolf algorithm (IGWO-ERF) was proposed to solve the problems mentioned above. First, IGWO-ERF imports the Cosine model to nonlinearize the linearly changing convergence factor α to balance the global exploration and local exploitation capabilities of the algorithm. Then, in the later stage of the algorithm iteration, α wolf generates its mirror wolf based on the lens imaging learning strategy to increase the diversity of the population and prevent local optimum of the population. The electric pitch system fault detection method of the wind turbine generator set sets the generator power of the variable pitch system as the main state parameter. First, it uses the Pearson correlation coefficient method to eliminate the features with low correlation with the electric pitch system generator power. Then, the remaining features are ranked by the importance of the RF features. Finally, the top N features are selected to construct the electric pitch system fault data set. The data set is divided into a training set and a test set. The training set is used to train the proposed fault detection model, and the test set is used for testing. Compared with other parameter optimization algorithms, the proposed method has lower FNR and FPR in the electric pitch system fault detection of the wind turbine generator set.

Food Tray Sealing Fault Detection in Multi-Spectral Images Using Data Fusion and Deep Learning Techniques

A correct food tray sealing is required to preserve food properties and safety for consumers. Traditional food packaging inspections are made by human operators to detect seal defects. Recent advances in the field of food inspection have been related to the use of hyperspectral imaging technology and automated vision-based inspection systems. A deep learning-based approach for food tray sealing fault detection using hyperspectral images is described. Several pixel-based image fusion methods are proposed to obtain 2D images from the 3D hyperspectral image datacube, which feeds the deep learning (DL) algorithms. Instead of considering all spectral bands in region of interest around a contaminated or faulty seal area, only relevant bands are selected using data fusion. These techniques greatly improve the computation time while maintaining a high classification ratio, showing that the fused image contains enough information for checking a food tray sealing state (faulty or normal), avoiding feeding a large image datacube to the DL algorithms. Additionally, the proposed DL algorithms do not require any prior handcraft approach, i.e., no manual tuning of the parameters in the algorithms are required since the training process adjusts the algorithm. The experimental results, validated using an industrial dataset for food trays, along with different deep learning methods, demonstrate the effectiveness of the proposed approach. In the studied dataset, an accuracy of 88.7%, 88.3%, 89.3%, and 90.1% was achieved for Deep Belief Network (DBN), Extreme Learning Machine (ELM), Stacked Auto Encoder (SAE), and Convolutional Neural Network (CNN), respectively.

A Satellite Incipient Fault Detection Method Based on Decomposed Kullback-Leibler Divergence

Detection of faults at the incipient stage is critical to improving the availability and continuity of satellite services. The application of a local optimum projection vector and the Kullback-Leibler (KL) divergence can improve the detection rate of incipient faults. However, this suffers from the problem of high time complexity. We propose decomposing the KL divergence in the original optimization model and applying the property of the generalized Rayleigh quotient to reduce time complexity. Additionally, we establish two distribution models for subfunctions F1(w) and F3(w) to detect the slight anomalous behavior of the mean and covariance. The effectiveness of the proposed method was verified through a numerical simulation case and a real satellite fault case. The results demonstrate the advantages of low computational complexity and high sensitivity to incipient faults.

A Hybrid SVD-Based Denoising and Self-Adaptive TMSST for High-Speed Train Axle Bearing Fault Detection

Fault detection of axle bearings is crucial to promote the safe, efficient, and reliable running of high-speed trains. In recent decades, time−frequency analysis (TFA) techniques have been widely used in mechanical equipment fault diagnoses. Time-reassigned multisynchrosqueezing transform (TMSST), as a novel time−frequency representation (TFR) algorithm, is more suitable for dealing with strong frequency-varying signals. However, TMSST TFR results are subject to noise interference. It is difficult to extract the accurate time−frequency (TF) fault feature of the axle bearing under a complex working environment. In addition, determination of the TMSST algorithm parameters depends on the personnel’s subjective experience. Therefore, the TMSST result has a great randomicity and has the disadvantage of having a poor reliability. To address the above issues, a hybrid SVD-based denoising and self-adaptive TMSST is proposed for axle bearing fault detection in this paper. The main improvements of the proposed algorithm include the following two aspects: (1) An SVD-based denoising method using the maximum SV mean to determine the reasonable SV order is adopted to eliminate noise interference and to reserve useful fault impulse information. (2) A new evaluation metric, named time−frequency spectrum permutation entropy (TFS-PEn), is put forward for the quantitative evaluation of the performance of TFR for the TMSST, and then a water cycle algorithm (WCA)-based optimized TMSST can adaptively determine the optimal algorithm parameters. In both the simulation and experimental tests, the superiority and effectiveness of the proposed method is compared with the TMSST, short-time Fourier transform (STFT), MSST, wavelet transform (WT), and Hilbert-Huang transform (HHT) methods. The results show that the proposed algorithm has a better performance for extracting the weak fault features of axle bearing under a strong background noise environment.

A Deep Learning-Based Fault Detection Model for Optimization of Shipping Operations and Enhancement of Maritime Safety

The ability to exploit data for obtaining useful and actionable information and for providing insights is an essential element for continuous process improvements. Recognizing the value of data as an asset, marine engineering puts data considerations at the core of system design. Used wisely, data can help the shipping sector to achieve operating cost savings and efficiency increase, higher safety, wellness of crew rates, and enhanced environmental protection and security of assets. The main goal of this study is to develop a methodology able to harmonize data collected from various sensors onboard and to implement a scalable and responsible artificial intelligence framework, to recognize patterns that indicate early signs of defective behavior in the operational state of the vessel. Specifically, the methodology examined in the present study is based on a 1D Convolutional Neural Network (CNN) being fed time series directly from the available dataset. For this endeavor, the dataset undergoes a preprocessing procedure. Aspiring to determine the effect of the parameters composing the networks and the values that ensure the best performance, a parametric inquiry is presented, determining the impact of the input period and the degree of degradation that our models identify adequately. The results provide an insightful picture of the applicability of 1D-CNN models in performing condition monitoring in ships, which is not thoroughly examined in the maritime sector for condition monitoring. The data modeling along with the development of the neural networks was undertaken with the Python programming language.

A Method for Real-Time Fault Detection of Liquid Rocket Engine Based on Adaptive Genetic Algorithm Optimizing Back Propagation Neural Network

A real-time fault diagnosis method utilizing an adaptive genetic algorithm to optimize a back propagation (BP) neural network is intended to achieve real-time fault detection of a liquid rocket engine (LRE). In this paper, the authors employ an adaptive genetic algorithm to optimize a BP neural network, produce real-time predictions regarding sensor data, compare the projected value to the actual data collected, and determine whether the engine is malfunctioning using a threshold judgment mechanism. The proposed fault detection method is simulated and verified using data from a certain type of liquid hydrogen and liquid oxygen rocket engine. The experiment results show that this method can effectively diagnose this liquid hydrogen and liquid oxygen rocket engine in real-time. The proposed method has higher system sensitivity and robustness compared with the results obtained from a single BP neural network model and a BP neural network model optimized by a traditional genetic algorithm (GA), and the method has engineering application value.

Soft Sensing for On-Line Fault Detection of Ammonium Sensors in Water Resource Recovery Facilities

The increasing demand for online sensors applied to advanced control strategies in water resource recovery facilities has resulted in the increasing investigation of fault-detection methods to improve the reliability of sensors installed in harsh environments. The study herein focuses on the fault detection of ammonium sensors, especially for effluent monitoring, given their potential in ammonium-based aeration control applications. An artificial neural network model was built to predict the ammonium content in the effluent by employing the information from five other sensors installed in the activated sludge tank: NH₄⁺, pH, ORP, DO, and TSS. The residual between the model prediction and the effluent ammonium sensor signal was utilized in a fault-detection mechanism based on principal component analysis and Shewhart monitoring charts. In contrast to previous studies, the present work utilizes typical faults collected from a 1 year historic dataset of an actual sensor setup. Treatment process anomalies, calibration bias faults, and fouling drifts were the most common issues identified from the historic dataset, and they were promptly identified by the proposed fault-detection methodology. Once a fault is detected, the model prediction can be actively used in place of the sensor for process control without affecting the treatment process by utilizing faulty datasets.

Open-Circuit Fault Detection and Classification of Modular Multilevel Converters in High Voltage Direct Current Systems (MMC-HVDC) with Long Short-Term Memory (LSTM) Method

Fault detection and classification are two of the challenging tasks in Modular Multilevel Converters in High Voltage Direct Current (MMC-HVDC) systems. To directly classify the raw sensor data without certain feature extraction and classifier design, a long short-term memory (LSTM) neural network is proposed and used for seven states of the MMC-HVDC transmission power system simulated by Power Systems Computer Aided Design/Electromagnetic Transients including DC (PSCAD/EMTDC). It is observed that the LSTM method can detect faults with 100% accuracy and classify different faults as well as provide promising fault classification performance. Compared with a bidirectional LSTM (BiLSTM), the LSTM can get similar classification accuracy, requiring less training time and testing time. Compared with Convolutional Neural Networks (CNN) and AutoEncoder-based deep neural networks (AE-based DNN), the LSTM method can get better classification accuracy around the middle of the testing data proportion, but it needs more training time.

A Data-Driven Scheme for Fault Detection of Discrete-Time Switched Systems

This paper is concerned with the fault detection issue for a class of discrete-time switched systems via the data-driven approach. For the fault detection of switched systems, it is inevitable to consider the mode matching problem between the activated subsystem and the executed residual generator since the mode mismatching may cause a false fault alarm in all probability. Frequently, studies assume that the switching laws are available to the residual generator, by which the residual generator keeps the same mode as the system plant and then the mode mismatching is excluded. However, this assumption is conservative and impractical because many switching laws are hard to acquire in practical applications. This work focuses on the case of switched systems with unavailable switching laws. In view of the unavailability of switching information, the mode recognition is considered for the fault detection process and meanwhile, sufficient conditions are presented for the mode distinguishability. Moreover, a novel decision logic for the fault detection is proposed, based on which new algorithms are established for the data-driven realization. Finally, a benchmark case on a three-tank system is used to illustrate the feasibility and usefulness of the obtained results.

Data-Driven Fault Diagnosis for Electric Drives: A Review

The need to manufacture more competitive equipment, together with the emergence of the digital technologies from the so-called Industry 4.0, have changed many paradigms of the industrial sector. Presently, the trend has shifted to massively acquire operational data, which can be processed to extract really valuable information with the help of Machine Learning or Deep Learning techniques. As a result, classical Condition Monitoring methodologies, such as model- and signal-based ones are being overcome by data-driven approaches. Therefore, the current paper provides a review of these data-driven active supervision strategies implemented in electric drives for fault detection and diagnosis (FDD). Hence, first, an overview of the main FDD methods is presented. Then, some basic guidelines to implement the Machine Learning workflow on which most data-driven strategies are based, are explained. In addition, finally, the review of scientific articles related to the topic is provided, together with a discussion which tries to identify the main research gaps and opportunities.

Experimental Analysis in Hadoop MapReduce: A Closer Look at Fault Detection and Recovery Techniques

Hadoop MapReduce reactively detects and recovers faults after they occur based on the static heartbeat detection and the re-execution from scratch techniques. However, these techniques lead to excessive response time penalties and inefficient resource consumption during detection and recovery. Existing fault-tolerance solutions intend to mitigate the limitations without considering critical conditions such as fail-slow faults, the impact of faults at various infrastructure levels and the relationship between the detection and recovery stages. This paper analyses the response time under two main conditions: fail-stop and fail-slow, when they manifest with node, service, and the task at runtime. In addition, we focus on the relationship between the time for detecting and recovering faults. The experimental analysis is conducted on a real Hadoop cluster comprising MapReduce, YARN and HDFS frameworks. Our analysis shows that the recovery of a single fault leads to an average of 67.6% response time penalty. Even though the detection and recovery times are well-turned, data locality and resource availability must also be considered to obtain the optimum tolerance time and the lowest penalties.

An optimized machine learning technology scheme and its application in fault detection in wireless sensor networks

Aiming at the problem of fault detection in data collection in wireless sensor networks, this paper combines evolutionary computing and machine learning to propose a productive technical solution. We choose the classical particle swarm optimization (PSO) and improve it, including the introduction of a biological population model to control the population size, and the addition of a parallel mechanism for further tuning. The proposed RS-PPSO algorithm was successfully used to optimize the initial weights and biases of back propagation neural network (BPNN), shortening the training time and raising the prediction accuracy. Wireless sensor networks (WSN) has become the key supporting platform of Internet of Things (IoT). The correctness of the data collected by the sensor nodes has a great influence on the reliability, real-time performance and energy saving of the entire network. The optimized machine learning technology scheme given in this paper can effectively identify the fault data, so as to ensure the effective operation of WSN.

Fault Detection and Isolation of the Multi-Sensor Inertial System

In order to solve the problem that the generalized likelihood test method cannot isolate the single fault of the four-gyro system and the double faults of the six-gyro system, a fault detection and isolation method combining the generalized likelihood test method with the residual error of the metabolism grey model is presented. The problem of isolating the single fault of the four-gyro system and the double faults of the six-gyro system using the generalized likelihood test method is analyzed. The method and process of fault detection and isolation are designed. The validity of the method presented in this paper is verified by simulation tests of the single fault of the four-gyro system and the double faults of the six-gyro system. By comparing the isolation performance with the generalized likelihood test method, it is proved that the isolation performance of the method proposed in this paper is better than that of the generalized likelihood test method. The method mentioned in this paper can effectively realize fault detection and isolation of the multi-gyro system and improve the inertial system’s reliability.

Contrastive Learning for Fault Detection and Diagnostics in the Context of Changing Operating Conditions and Novel Fault Types

Reliable fault detection and diagnostics are crucial in order to ensure efficient operations in industrial assets. Data-driven solutions have shown great potential in various fields but pose many challenges in Prognostics and Health Management (PHM) applications: Changing external in-service factors and operating conditions cause variations in the condition monitoring (CM) data resulting in false alarms. Furthermore, novel types of faults can also cause variations in CM data. Since faults occur rarely in complex safety critical systems, a training dataset typically does not cover all possible fault types. To enable the detection of novel fault types, the models need to be sensitive to novel variations. Simultaneously, to decrease the false alarm rate, invariance to variations in CM data caused by changing operating conditions is required. We propose contrastive learning for the task of fault detection and diagnostics in the context of changing operating conditions and novel fault types. In particular, we evaluate how a feature representation trained by the triplet loss is suited to fault detection and diagnostics under the aforementioned conditions. We showcase that classification and clustering based on the learned feature representations are (1) invariant to changing operating conditions while also being (2) suited to the detection of novel fault types. Our evaluation is conducted on the bearing benchmark dataset provided by the Case Western Reserve University (CWRU).

Comparison of Novelty Detection Methods for Detection of Various Rotary Machinery Faults

Condition monitoring is an indispensable element related to the operation of rotating machinery. In this article, the monitoring system for the parallel gearbox was proposed. The novelty detection approach is used to develop the condition assessment support system, which requires data collection for a healthy structure. The measured signals were processed to extract quantitative indicators sensitive to the type of damage occurring in this type of structure. The indicator's values were used for the development of four different novelty detection algorithms. Presented novelty detection models operate on three principles: feature space distance, probability distribution, and input reconstruction. One of the distance-based models is adaptive, adjusting to new data flowing in the form of a stream. The authors test the developed algorithms on experimental and simulation data with a similar distribution, using the training set consisting mainly of samples generated by the simulator. Presented in the article results demonstrate the effectiveness of the trained models on both data sets.

Mechanical Damage Assessment for Pneumatic Control Valves Based on a Statistical Reliability Model

A reliability assessment is an important tool used for processing plants, since the facility consists of many loops and instruments attached and operated based on other availability; thus, a statistical model is needed to visualize the reliability of its operation. The paper focuses on the reliability assessment and prediction based on the existing statistical models, such as normal, log-normal, exponential, and Weibull distribution. This paper evaluates and visualizes the statistical reliability models optimized using MLE and considers the failure mode caused during a simulated process control operation. We simulated the failure of the control valve caused by stiction running with various flow rates using a pilot plant, which depicted the Weibull distribution as the best model to estimate the simulated process failure.

Human-in-the-Loop Insulin Dosing

The last ten years of efforts in developing automated insulin dosing systems have led to one hybrid closed-loop device in the US market with more in the late stages of development. Much of the focus has been on algorithms, including closed-loop, detection of sensor and pump faults, and safety. There has been less discussion in the open literature about user interface design and related options. This article provides perspectives on automated insulin delivery (AID) system design by analyzing commonly used devices, such as bicycles and car entertainment systems. The recent Boeing 737 Max 8 disasters are used to highlight related challenges with AID systems. The role that system engineers can play in the do it yourself artificial pancreas system movement is also discussed. The human-in-the-loop remains by far the most important "component" of any AID system.