Browsing by Subject "Fault detection"
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Item Development of New Whole Building Fault Detection and Diagnosis Techniques for Commissioning Persistence(2012-12-07) Lin, GuanjingCommercial building owners spent $167 billion for energy in 2006. Building commissioning services have proven to be successful in saving building energy consumption. However, the optimal energy performance obtained by commissioning may subsequently degrade. The persistence of savings is of significant interest. For commissioning persistence, two statistical approaches, Days Exceeding Threshold-Date (DET-Date) method and Days Exceeding Threshold-Outside Air Temperature (DET-Toa) method, are developed to detect abnormal whole building energy consumption, and two approaches called Cosine Similarity method and Euclidean Distance Similarity method are developed to isolate the possible fault reasons. The effectiveness of these approaches is demonstrated and compared through tests in simulation and real buildings. The impacts of the factors including calibrated simulation model accuracy, fault severity, the time of fault occurrence, reference control change magnitude setting, and fault period length are addressed in the sensitivity study. The study shows that the DET-Toa method and the Cosine Similarity method are superior and more useful for the whole building fault detection and diagnosis.Item Fault detection and model-based diagnostics in nonlinear dynamic systems(2010-12) Nakhaeinejad, Mohsen; Bryant, Michael D.; Driga, Mircea D.; Fahrenthold, Eric P.; Fernandez, Benito; Longoria, Raul G.Modeling, fault assessment, and diagnostics of rolling element bearings and induction motors were studied. Dynamic model of rolling element bearings with faults were developed using vector bond graphs. The model incorporates gyroscopic and centrifugal effects, contact deflections and forces, contact slip and separations, and localized faults. Dents and pits on inner race, outer race and balls were modeled through surface profile changes. Experiments with healthy and faulty bearings validated the model. Bearing load zones under various radial loads and clearances were simulated. The model was used to study dynamics of faulty bearings. Effects of type, size and shape of faults on the vibration response and on dynamics of contacts in presence of localized faults were studied. A signal processing algorithm, called feature plot, based on variable window averaging and time feature extraction was proposed for diagnostics of rolling element bearings. Conducting experiments, faults such as dents, pits, and rough surfaces on inner race, balls, and outer race were detected and isolated using the feature plot technique. Time features such as shape factor, skewness, Kurtosis, peak value, crest factor, impulse factor and mean absolute deviation were used in feature plots. Performance of feature plots in bearing fault detection when finite numbers of samples are available was shown. Results suggest that the feature plot technique can detect and isolate localized faults and rough surface defects in rolling element bearings. The proposed diagnostic algorithm has the potential for other applications such as gearbox. A model-based diagnostic framework consisting of modeling, non-linear observability analysis, and parameter tuning was developed for three-phase induction motors. A bond graph model was developed and verified with experiments. Nonlinear observability based on Lie derivatives identified the most observable configuration of sensors and parameters. Continuous-discrete Extended Kalman Filter (EKF) technique was used for parameter tuning to detect stator and rotor faults, bearing friction, and mechanical loads from currents and speed signals. A dynamic process noise technique based on the validation index was implemented for EKF. Complex step Jacobian technique improved computational performance of EKF and observability analysis. Results suggest that motor faults, bearing rotational friction, and mechanical load of induction motors can be detected using model-based diagnostics as long as the configuration of sensors and parameters is observable.Item Fault detection and precedent-free localization in thermal-fluid systems(2010-12) Carpenter, Katherine Patricia; Djurdjanovic, Dragan; Da Silva, Alexandre K., 1975-This thesis presents a method for fault detection and precedent-free isolation for two types of channel flow systems, which were modeled with the finite element method. Unlike previous fault detection methods, this method requires no a priori knowledge or training pertaining to any particular fault. The basis for anomaly detection was the model of normal behavior obtained using the recently introduced Growing Structure Multiple Model System (GSMMS). Anomalous behavior is then detected as statistically significant departures of the current modeling residuals away from the modeling residuals corresponding to the normal system behavior. Distributed anomaly detection facilitated by multiple anomaly detectors monitoring various parts of the thermal-fluid system enabled localization of anomalous partitions of the system without the need to train classifiers to recognize an underlying fault.Item Improving process monitoring and modeling of batch-type plasma etching tools(2015-05) Lu, Bo, active 21st century; Edgar, Thomas F.; Stuber, John D; Djurdjanovic, Dragan; Ekerdt, John G; Bonnecaze, Roger T; Baldea, MichaelManufacturing equipments in semiconductor factories (fabs) provide abundant data and opportunities for data-driven process monitoring and modeling. In particular, virtual metrology (VM) is an active area of research. Traditional monitoring techniques using univariate statistical process control charts do not provide immediate feedback to quality excursions, hindering the implementation of fab-wide advanced process control initiatives. VM models or inferential sensors aim to bridge this gap by predicting of quality measurements instantaneously using tool fault detection and classification (FDC) sensor measurements. The existing research in the field of inferential sensor and VM has focused on comparing regressions algorithms to demonstrate their feasibility in various applications. However, two important areas, data pretreatment and post-deployment model maintenance, are usually neglected in these discussions. Since it is well known that the industrial data collected is of poor quality, and that the semiconductor processes undergo drifts and periodic disturbances, these two issues are the roadblocks in furthering the adoption of inferential sensors and VM models. In data pretreatment, batch data collected from FDC systems usually contain inconsistent trajectories of various durations. Most analysis techniques requires the data from all batches to be of same duration with similar trajectory patterns. These inconsistencies, if unresolved, will propagate into the developed model and cause challenges in interpreting the modeling results and degrade model performance. To address this issue, a Constrained selective Derivative Dynamic Time Warping (CsDTW) method was developed to perform automatic alignment of trajectories. CsDTW is designed to preserve the key features that characterizes each batch and can be solved efficiently in polynomial time. Variable selection after trajectory alignment is another topic that requires improvement. To this end, the proposed Moving Window Variable Importance in Projection (MW-VIP) method yields a more robust set of variables with demonstrably more long-term correlation with the predicted output. In model maintenance, model adaptation has been the standard solution for dealing with drifting processes. However, most case studies have already preprocessed the model update data offline. This is an implicit assumption that the adaptation data is free of faults and outliers, which is often not true for practical implementations. To this end, a moving window scheme using Total Projection to Latent Structure (T-PLS) decomposition screens incoming updates to separate the harmless process noise from the outliers that negatively affects the model. The integrated approach was demonstrated to be more robust. In addition, model adaptation is very inefficient when there are multiplicities in the process, multiplicities could occur due to process nonlinearity, switches in product grade, or different operating conditions. A growing structure multiple model system using local PLS and PCA models have been proposed to improve model performance around process conditions with multiplicity. The use of local PLS and PCA models allows the method to handle a much larger set of inputs and overcome several challenges in mixture model systems. In addition, fault detection sensitivities are also improved by using the multivariate monitoring statistics of these local PLS/PCA models. These proposed methods are tested on two plasma etch data sets provided by Texas Instruments. In addition, a proof of concept using virtual metrology in a controller performance assessment application was also tested.Item Low cost fault detection system for railcars and tracks(Texas A&M University, 2004-09-30) Vengalathur, Sriram T.A "low cost fault detection system" that identifies wheel flats and defective tracks is explored here. This is achieved with the conjunction of sensors, microcontrollers and Radio Frequency (RF) transceivers. The objective of the proposed research is to identify faults plaguing railcars and to be able to clearly distinguish the faults of a railcar from the inherent faults in the track. The focus of the research though, is mainly to identify wheel flats and defective tracks. The thesis has been written with the premise that the results from the simulation software GENSYS are close to the real time data that would have been obtained from an actual railcar. Based on the results of GENSYS, a suitable algorithm is written that helps segregate a fault in a railcar from a defect in a track. The above code is implemented using hardware including microcontrollers, accelerometers, RF transceivers and a real time monitor. An enclosure houses the system completely, so that it is ready for application in a real environment. This also involves selection of suitable hardware so that there is a uniform source of power supply that reduces the cost and assists in building a robust system.Item Precedent-free fault isolation in a diesel engine EGR valve system(2009-12) Cholette, Michael Edward; Djurdjanovic, Dragan; Fernandez, Benito R.An application of a recently introduced framework for isolating unprecedented faults for an automotive engine EGR valve system is presented. Using normal behavior data generated by a high fidelity engine simulation, the Growing Structure Multiple Model System (GSMMS) is used to construct models of normal behavior for EGR valve system and its various subsystems. Using the GSMMS models as a foundation, anomalous behavior of the entire system is then detected as statistically significant departures of the most recent modeling residuals from the modeling residuals during normal behavior. By reconnecting anomaly detectors to the constituent subsystems, the anomaly can be isolated without the need for prior training using faulty data. Furthermore, faults that were previously encountered (and modeled) are recognized using the same approach as the anomaly detectors.Item Visualization of multivariate process data for fault detection and diagnosis(2014-05) Wang, Ray Chen; Baldea, Michael; Edgar, Thomas F.This report introduces the concept of three-dimensional (3D) radial plots for the visualization of multivariate large scale datasets in plant operations. A key concept of this representation of data is the introduction of time as the third dimension in a two dimensional radial plot, which allows for the display of time series data in any number of process variables. This report shows the ability of 3D radial plots to conduct systemic fault detection and classification in chemical processes through the use of confidence ellipses, which capture the desired operating region of process variables during a defined period of steady-state operation. Principal component analysis (PCA) is incorporated into the method to reduce multivariate interactions and the dimensionality of the data. The method is applied to two case studies with systemic faults present (compressor surge and column flooding) as well as data obtained from the Tennessee Eastman simulator, which contained localized faults. Fault classification using the interior angles of the radial plots is also demonstrated in the paper.