Intelligent Fault Diagnosis and Prognosis for Engineering System....pdf

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Cover

Contents

Chapter1

Chapter2

Chapter 3 Sensors and Sensing Strategies

Chapter4

Chapter5

Chapter6

Chapter7

Chapter8

Appendix

Index

INTELLIGENT FAULT DIAGNOSIS AND PROGNOSIS FOR ENGINEERING SYSTEMS Intelligent Fault Diagnosis and Prognosis for Engineering Systems. G. Vachtsevanos, F. Lewis, M. Roemer A. Hess and B. Wu © 2006 John Wiley & Sons, Inc. ISBN: 978-0-471-72999-0

INTELLIGENT FAULT DIAGNOSIS AND PROGNOSIS FOR ENGINEERING SYSTEMS GEORGE VACHTSEVANOS FRANK LEWIS MICHAEL ROEMER ANDREW HESS BIQING WU JOHN WILEY & SONS, INC.

This book is printed on acid-free paper. 嘷⬁ Copyright 䉷 2006 by John Wiley & Sons, Inc. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey Published simultaneously in Canada. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 646-8600, or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, or online at www.wiley.com / go / permissions. Limit of Liability / Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and speciﬁcally disclaim any implied warranties of merchantability or ﬁtness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor the author shall be liable for any loss of proﬁt or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information about our other products and services, please contact our Customer Care Department within the United States at (800) 762-2974, outside the United States at (317) 572-3993 or fax (317) 572-4002. Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic books. For more information about Wiley products, visit our web site at www.wiley.com. Library of Congress Cataloging-in-Publication Data: Intelligent fault diagnosis and prognosis for engineering systems / George Vachtsevanos . . . [et al.]. p. cm. Includes bibliographical references and index. ISBN-13: 978-0-0471-72999-0 (cloth) ISBN-10: 0-471-72999-X (cloth) 1. Fault location (Engineering) 2. System analysis. fault diagnosis and prognosis for engineering systems. George J. I. Title: Intelligent II. Vachtsevanos, TA169.6.I68 2006 620⬘.0044—dc22 Printed in the United States of America 10 9 8 7 6 5 4 3 2 1 2006005574

To my wife Athena. G.V. To Roma, my son. F.L.L. To my wife Sharon, son Michael, and daughter Aubrey. M.J.R. To my parents, Yanying Chen and Qingliang Wu. B.W.

CONTENTS PREFACE ACKNOWLEDGMENTS PROLOGUE 1 INTRODUCTION 1.1 1.2 1.3 1.4 1.5 1.6 Historical Perspective / 1 Diagnostic and Prognostic System Requirements / 3 Designing in Fault Diagnostic and Prognostic Systems / 4 Diagnostic and Prognostic Functional Layers / 5 Preface to Book Chapters / 7 References / 12 2 SYSTEMS APPROACH TO CBM/PHM 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Introduction / 13 Trade Studies / 16 Failure Modes and Effects Criticality Analysis (FMECA) / 18 System CBM Test-Plan Design / 26 Performance Assessment / 28 CBM/PHM Impact on Maintenance and Operations: Case Studies / 37 CBM/PHM in Control and Contingency Management / 49 References / 54 xi xiii xv 1 13 vii

viii CONTENTS 3 SENSORS AND SENSING STRATEGIES Introduction / 56 Sensors / 57 Sensor Placement / 77 3.1 3.2 3.3 3.4 Wireless Sensor Networks / 80 3.5 3.6 Smart Sensors / 89 References / 91 4 SIGNAL PROCESSING AND DATABASE MANAGEMENT SYSTEMS 56 95 4.1 4.2 4.3 4.4 4.5 4.6 Introduction / 95 Signal Processing in CBM/PHM / 96 Signal Preprocessing / 97 Signal Processing / 104 Vibration Monitoring and Data Analysis / 128 Real-Time Image Feature Extraction and Defect/Fault Classiﬁcation / 146 The Virtual Sensor / 150 Fusion or Integration Technologies / 152 Usage-Pattern Tracking / 162 4.7 4.8 4.9 4.10 Database Management Methods / 163 4.11 References / 165 5 FAULT DIAGNOSIS 172 Introduction / 172 The Diagnostic Framework / 175 Historical Data Diagnostic Methods / 181 Data-Driven Fault Classiﬁcation and Decision Making / 191 Dynamic Systems Modeling / 211 Physical Model–Based Methods / 227 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Model-Based Reasoning / 235 5.8 5.9 5.10 A Diagnostic Framework for Electrical/Electronic Case-Based Reasoning (CBR) / 243 Other Methods for Fault Diagnosis / 258 Systems / 267 5.11 Case Study: Vibration-Based Fault Detection and Diagnosis for Engine Bearings / 271 5.12 References / 279

6 FAULT PROGNOSIS CONTENTS ix 284 Introduction / 284 6.1 6.2 Model-Based Prognosis Techniques / 289 6.3 6.4 6.5 6.6 Probability-Based Prognosis Techniques / 301 Data-Driven Prediction Techniques / 312 Case Studies / 333 References / 351 7 FAULT DIAGNOSIS AND PROGNOSIS PERFORMANCE METRICS 355 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 Introduction / 355 CBM/PHM Requirements Deﬁnition / 356 Feature-Evaluation Metrics / 358 Fault Diagnosis Performance Metrics / 362 Prognosis Performance Metrics / 385 Diagnosis and Prognosis Effectiveness Metrics / 395 Complexity/Cost-Beneﬁt Analysis of CBM/PHM Systems / 396 References / 398 8 LOGISTICS: SUPPORT OF THE SYSTEM IN OPERATION 400 8.1 8.2 Introduction / 400 Product-Support Architecture, Knowledge Base, and Methods for CBM / 401 Product Support without CBM / 404 Product Support with CBM / 405 8.3 8.4 8.5 Maintenance Scheduling Strategies / 409 8.6 8.7 A Simple Example / 410 References / 416 APPENDIX INDEX 417 424

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