Intelligent Fault Diagnosis and Prognosis for Engineering Systems.pdf

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INTELLIGENTFAULTDIAGNOSISANDPROGNOSISFORENGINEERINGSYSTEMSIntelligent Fault Diagnosis and Prognosis for Engineering Systems. G. Vachtsevanos, F. Lewis, M. RoemerA. Hess and B. Wu © 2006 John Wiley & Sons, Inc. ISBN: 978-0-471-72999-0

INTELLIGENTFAULTDIAGNOSISANDPROGNOSISFORENGINEERINGSYSTEMSGEORGEVACHTSEVANOSFRANKLEWISMICHAELROEMERANDREWHESSBIQINGWUJOHNWILEY&SONS,INC.

Thisbookisprintedonacid-freepaper.嘷⬁Copyright䉷2006byJohnWiley&Sons,Inc.Allrightsreserved.PublishedbyJohnWiley&Sons,Inc.,Hoboken,NewJerseyPublishedsimultaneouslyinCanada.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans,electronic,mechanical,photocopying,recording,scanning,orotherwise,exceptaspermittedunderSection107or108ofthe1976UnitedStatesCopyrightAct,withouteitherthepriorwrittenpermissionofthePublisher,orauthorizationthroughpaymentoftheappropriateper-copyfeetotheCopyrightClearanceCenter,222RosewoodDrive,Danvers,MA01923,(978)750-8400,fax(978)646-8600,oronthewebatwww.copyright.com.RequeststothePublisherforpermissionshouldbeaddressedtothePermissionsDepartment,JohnWiley&Sons,Inc.,111RiverStreet,Hoboken,NJ07030,(201)748-6011,fax(201)748-6008,oronlineatwww.wiley.com/go/permissions.LimitofLiability/DisclaimerofWarranty:Whilethepublisherandauthorhaveusedtheirbesteffortsinpreparingthisbook,theymakenorepresentationsorwarrantieswithrespecttotheaccuracyorcompletenessofthecontentsofthisbookandspeciﬁcallydisclaimanyimpliedwarrantiesofmerchantabilityorﬁtnessforaparticularpurpose.Nowarrantymaybecreatedorextendedbysalesrepresentativesorwrittensalesmaterials.Theadviceandstrategiescontainedhereinmaynotbesuitableforyoursituation.Youshouldconsultwithaprofessionalwhereappropriate.Neitherthepublishernortheauthorshallbeliableforanylossofproﬁtoranyothercommercialdamages,includingbutnotlimitedtospecial,incidental,consequential,orotherdamages.Forgeneralinformationaboutourotherproductsandservices,pleasecontactourCustomerCareDepartmentwithintheUnitedStatesat(800)762-2974,outsidetheUnitedStatesat(317)572-3993orfax(317)572-4002.Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprintmaynotbeavailableinelectronicbooks.FormoreinformationaboutWileyproducts,visitourwebsiteatwww.wiley.com.LibraryofCongressCataloging-in-PublicationData:Intelligentfaultdiagnosisandprognosisforengineeringsystems/GeorgeVachtsevanos...[etal.].p.cm.Includesbibliographicalreferencesandindex.ISBN-13:978-0-0471-72999-0(cloth)ISBN-10:0-471-72999-X(cloth)1.Faultlocation(Engineering)2.Systemanalysis.I.Title:Intelligentfaultdiagnosisandprognosisforengineeringsystems.II.Vachtsevanos,GeorgeJ.TA169.6.I682006620⬘.0044—dc222006005574PrintedintheUnitedStatesofAmerica10987654321

TomywifeAthena.G.V.ToRoma,myson.F.L.L.TomywifeSharon,sonMichael,anddaughterAubrey.M.J.R.Tomyparents,YanyingChenandQingliangWu.B.W.

viiCONTENTSPREFACExiACKNOWLEDGMENTSxiiiPROLOGUExv1INTRODUCTION11.1HistoricalPerspective/11.2DiagnosticandPrognosticSystemRequirements/31.3DesigninginFaultDiagnosticandPrognosticSystems/41.4DiagnosticandPrognosticFunctionalLayers/51.5PrefacetoBookChapters/71.6References/122SYSTEMSAPPROACHTOCBM/PHM132.1Introduction/132.2TradeStudies/162.3FailureModesandEffectsCriticalityAnalysis(FMECA)/182.4SystemCBMTest-PlanDesign/262.5PerformanceAssessment/282.6CBM/PHMImpactonMaintenanceandOperations:CaseStudies/372.7CBM/PHMinControlandContingencyManagement/492.8References/54

viiiCONTENTS3SENSORSANDSENSINGSTRATEGIES563.1Introduction/563.2Sensors/573.3SensorPlacement/773.4WirelessSensorNetworks/803.5SmartSensors/893.6References/914SIGNALPROCESSINGANDDATABASEMANAGEMENTSYSTEMS954.1Introduction/954.2SignalProcessinginCBM/PHM/964.3SignalPreprocessing/974.4SignalProcessing/1044.5VibrationMonitoringandDataAnalysis/1284.6Real-TimeImageFeatureExtractionandDefect/FaultClassiﬁcation/1464.7TheVirtualSensor/1504.8FusionorIntegrationTechnologies/1524.9Usage-PatternTracking/1624.10DatabaseManagementMethods/1634.11References/1655FAULTDIAGNOSIS1725.1Introduction/1725.2TheDiagnosticFramework/1755.3HistoricalDataDiagnosticMethods/1815.4Data-DrivenFaultClassiﬁcationandDecisionMaking/1915.5DynamicSystemsModeling/2115.6PhysicalModel–BasedMethods/2275.7Model-BasedReasoning/2355.8Case-BasedReasoning(CBR)/2435.9OtherMethodsforFaultDiagnosis/2585.10ADiagnosticFrameworkforElectrical/ElectronicSystems/2675.11CaseStudy:Vibration-BasedFaultDetectionandDiagnosisforEngineBearings/2715.12References/279

CONTENTSix6FAULTPROGNOSIS2846.1Introduction/2846.2Model-BasedPrognosisTechniques/2896.3Probability-BasedPrognosisTechniques/3016.4Data-DrivenPredictionTechniques/3126.5CaseStudies/3336.6References/3517FAULTDIAGNOSISANDPROGNOSISPERFORMANCEMETRICS3557.1Introduction/3557.2CBM/PHMRequirementsDeﬁnition/3567.3Feature-EvaluationMetrics/3587.4FaultDiagnosisPerformanceMetrics/3627.5PrognosisPerformanceMetrics/3857.6DiagnosisandPrognosisEffectivenessMetrics/3957.7Complexity/Cost-BeneﬁtAnalysisofCBM/PHMSystems/3967.8References/3988LOGISTICS:SUPPORTOFTHESYSTEMINOPERATION4008.1Introduction/4008.2Product-SupportArchitecture,KnowledgeBase,andMethodsforCBM/4018.3ProductSupportwithoutCBM/4048.4ProductSupportwithCBM/4058.5MaintenanceSchedulingStrategies/4098.6ASimpleExample/4108.7References/416APPENDIX417INDEX424

xiPREFACECondition-basedmaintenance(CBM)andprognosticsandhealthmanagement(PHM)haveemergedoverrecentyearsassigniﬁcanttechnologiesthataremakinganimpactonbothmilitaryandcommercialmaintenancepractices.Weareindeedwitnessingatrueparadigmshiftinthewaycomplexdynamicsystems(aircraftandspacecraft,shipboardsystems,industrialandmanufac-turingprocesses,etc.)aredesigned,monitored,andmaintained.Faultdiag-nosisandprognosisofthefailingcomponent’sremainingusefullife,aswellaslogisticssupportactivitiesrequiredtomaintain,repair,oroverhaulsuchcriticalsystems,requireactivecontributionfrommultipledisciplines.CBMandPHMtechnologiesarecharacterizedbythemergingandstrongcouplingofinterdisciplinarytrendsfromtheengineeringsciences,computerscience,reliabilityengineering,communications,management,etc.Writingabookthatisnotmerelyaneditedcollectionoftechnicalpapersinthisareabutpresentssystematicallyandasthoroughlyaspossiblethediversesubjectmat-terfromsensorsandsystemsstudiestologisticsthereforeisachallengingandarduoustaskthatrequiresthecontributionsofmanyexpertsandthecompilationofsourceandreferencematerialacrossdisciplines.CBMandPHMtechnologiesareevolvingrapidly,theirpotentialapplica-tiondomainsareexpanding,andthecustomerbaseforthesetechnologiesisincreasingataphenomenalrate.Althoughtheytargetedinitiallytheequip-mentmaintainerastheenduser,substantialbeneﬁtsalsomayaccruefromtheirimplementationfortheoperator,theprocessmanagerorﬁeldcom-mander,andtheequipmentdesigner.ThelattercantakeadvantageofCBM/PHMstudiesinordertodesignorredesigncriticalsystemsorprocessessothattheyexhibitimprovedattributesoffaulttoleranceandhighconﬁdence.Itisthereforedifﬁcult,ifnotimpossible,tocaptureinasinglevolumeall

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