Engineering topics

Pattipati, Krishna R.

Publications and source records attributed to Pattipati, Krishna R..

12 records

DOE OSTI2022

Sensor selection and tool wear prediction with data‐driven models for precision machining

Abstract Estimation of tool wear in precision machining is vital in the traditional subtractive machining industry to reduce processing cost, improve manufacturing efficiency and product quality. In this vein, fusion of time and frequency‐domain features of commonly sensed signals can provide an early indication of tool wear and improve its prediction accuracy for prognostics and health management. This paper presents a data‐driven methodology and a complete tool chain for the inference of precision machining tool wear from fused machine measurements, such as cutting force, power, audio and vibration signals, and quantify the usefulness of each measurement. Indicators of tool wear are extracted from time‐domain signal statistics, frequency‐domain analysis, and time‐frequency domain analysis. Correlation coefficients between the extracted features (indicators) and the tool wear are used to select the most informative features. Principal Component Analysis and Partial Least‐Squares are used to reduce the dimensionality of the feature space. Regression models, including linear regression, support vector regression, Decision tree regression, neural network regression and Gaussian process regression, are used to predict the tool wear using data from a Haas milling machine performing spiral boss face milling. The performance of the regression models based on subsets of sensors validates the preliminary estimates about the saliency of the sensors. The experimental results show that the proposed methods can predict the machine tool wear precisely, with readily available sensor measurements. Neural network and Gaussian process regression were able to achieve good estimates of tool wear at different machine operating conditions. The most informative signal in predicting tool wear was shown to be the vibration signal. Time‐frequency domain features were the most informative features among the combination of features of three domains. In addition, using partial least squares components extracted from the original features of signals led to higher prediction accuracy.

Han, Seulki↗

DOE OSTI2022

Physics-based modeling and information-theoretic sensor and settings selection for tool wear detection in precision machining

Precision machining of metals is an energy intensive process with applications and impacts across the manufacturing industry. The energy efficiency, product yield, and maintenance of the precision machine require a digital twin that can assist with prognostics and health management. In this report a physics-based model is developed and validated against face milling data, and then used for the timely and precise inference of machining faults that cannot be measured directly. Computer numerical control (CNC) measurements of power and force are used through this physics-based machining model to predict deviations of the outputs of power consumption and cutting forces during normal operation. A model-based fault detection and isolation methodology is applied to determine the optimal (traditional and available) sensor suite and the test settings (admissible input values) that improve the inference of tool wear in face milling. The optimal sensor suite and input test settings are obtained by solving a mixed integer non-linear program that optimizes information-theoretic metrics relevant to the detection and isolation of tool wear from steady-state or transient machining measurements. Dynamic time warping and k—NN classification are then used to validate the robustness of the optimal design for fault detection test design, including the optimal sensor suite.

42 ENGINEERING↗

DOE OSTI2022

Hybrid data-driven and model-informed online tool wear detection in milling machines

Precision machining tool wear is responsible for low product throughput and quality. Monitoring the tool wear online is vital to prevent degradation in machining quality. However, direct real-time tool wear measurement is not practical. This paper presents residual-based anomaly detection models, combining a hybrid model comprised of a physics-based model and a data-driven model (a decision tree or a neural network) to predict signals of interest (e.g., power or forces) under nominal conditions, followed by Page’s cumulative sum test for detecting tool wear on-line using the computer numerical control machine measurements. The most informative features are ranked using dynamic programming and its approximation variants from real-time measurements and machine settings, such as the width of cut, depth of cut, feed rate and spindle speed, that serve as inputs to the predictive models. The baseline nominal model is incrementally updated with experimental data via a gradient boosted adaptation model to generate the residuals that account for discrepancies between the actual machine data under normal conditions and the baseline nominal model predictions. The hybrid model is validated against 20 Mazak milling machine experimental tests and one Haas run-to-failure experiment. The proposed anomaly detector is applied to synthetic data from simulations of the physics-based model at different operating conditions, measurement noise levels, and tool wear levels, and the methods were able to achieve an overall 92% accuracy in data with 1% noise. The anomaly detection methods based on hybrid model reduced the false alarms of either the data-driven or physical-based models alone, and are found to be capable of good online detection of tool wear.

42 ENGINEERING↗

DOE OSTI2021

Classification and regression models of audio and vibration signals for machine state monitoring in precision machining systems

Here we present a data-driven method for monitoring machine status in manufacturing processes. Audio and vibration data from precision machining are used for inference in two operating scenarios: (a) variable machine health states (anomaly detection); and (b) settings of machine operation (state estimation). Audio and vibration signals are first processed through Fast Fourier Transform and Principal Component Analysis to extract transformed and informative features. These features are then used in the training of classification and regression models for machine state monitoring. Specifically, three classifiers (K-nearest neighbors, convolutional neural networks and support vector machines) and two regressors (support vector regression and neural network regression) were explored, in terms of their accuracy in machine state prediction. It is shown that the audio and vibration signals are sufficiently rich in information about the machine that 100% state classification accuracy could be accomplished. Data fusion was also explored, showing overall superior accuracy of data-driven regression models.

42 ENGINEERING↗

NASA NTRS2005

Fault Diagnosis in HVAC Chillers

Modern buildings are being equipped with increasingly sophisticated power and control systems with substantial capabilities for monitoring and controlling the amenities. Operational problems associated with heating, ventilation, and air-conditioning (HVAC) systems plague many commercial buildings, often the result of degraded equipment, failed sensors, improper installation, poor maintenance, and improperly implemented controls. Most existing HVAC fault-diagnostic schemes are based on analytical models and knowledge bases. These schemes are adequate for generic systems. However, real-world systems significantly differ from the generic ones and necessitate modifications of the models and/or customization of the standard knowledge bases, which can be labor intensive. Data-driven techniques for fault detection and isolation (FDI) have a close relationship with pattern recognition, wherein one seeks to categorize the input-output data into normal or faulty classes. Owing to the simplicity and adaptability, customization of a data-driven FDI approach does not require in-depth knowledge of the HVAC system. It enables the building system operators to improve energy efficiency and maintain the desired comfort level at a reduced cost. In this article, we consider a data-driven approach for FDI of chillers in HVAC systems. To diagnose the faults of interest in the chiller, we employ multiway dynamic principal component analysis (MPCA), multiway partial least squares (MPLS), and support vector machines (SVMs). The simulation of a chiller under various fault conditions is conducted using a standard chiller simulator from the American Society of Heating, Refrigerating, and Air-conditioning Engineers (ASHRAE). We validated our FDI scheme using experimental data obtained from different types of chiller faults.

Choi, Kihoon↗

NASA NTRS2005

Experiments on Supervised Learning Algorithms for Text Categorization

Modern information society is facing the challenge of handling massive volume of online documents, news, intelligence reports, and so on. How to use the information accurately and in a timely manner becomes a major concern in many areas. While the general information may also include images and voice, we focus on the categorization of text data in this paper. We provide a brief overview of the information processing flow for text categorization, and discuss two supervised learning algorithms, viz., support vector machines (SVM) and partial least squares (PLS), which have been successfully applied in other domains, e.g., fault diagnosis [9]. While SVM has been well explored for binary classification and was reported as an efficient algorithm for text categorization, PLS has not yet been applied to text categorization. Our experiments are conducted on three data sets: Reuter's- 21578 dataset about corporate mergers and data acquisitions (ACQ), WebKB and the 20-Newsgroups. Results show that the performance of PLS is comparable to SVM in text categorization. A major drawback of SVM for multi-class categorization is that it requires a voting scheme based on the results of pair-wise classification. PLS does not have this drawback and could be a better candidate for multi-class text categorization.

Namburu, Setu Madhavi↗

NASA NTRS1997

Multiple Fault Isolation in Redundant Systems

Fault diagnosis in large-scale systems that are products of modern technology present formidable challenges to manufacturers and users. This is due to large number of failure sources in such systems and the need to quickly isolate and rectify failures with minimal down time. In addition, for fault-tolerant systems and systems with infrequent opportunity for maintenance (e.g., Hubble telescope, space station), the assumption of at most a single fault in the system is unrealistic. In this project, we have developed novel block and sequential diagnostic strategies to isolate multiple faults in the shortest possible time without making the unrealistic single fault assumption.

Pattipati, Krishna R.↗

NASA NTRS1997

Sequential Test Strategies for Multiple Fault Isolation

In this paper, we consider the problem of constructing near optimal test sequencing algorithms for diagnosing multiple faults in redundant (fault-tolerant) systems. The computational complexity of solving the optimal multiple-fault isolation problem is super-exponential, that is, it is much more difficult than the single-fault isolation problem, which, by itself, is NP-hard. By employing concepts from information theory and Lagrangian relaxation, we present several static and dynamic (on-line or interactive) test sequencing algorithms for the multiple fault isolation problem that provide a trade-off between the degree of suboptimality and computational complexity. Furthermore, we present novel diagnostic strategies that generate a static diagnostic directed graph (digraph), instead of a static diagnostic tree, for multiple fault diagnosis. Using this approach, the storage complexity of the overall diagnostic strategy reduces substantially. Computational results based on real-world systems indicate that the size of a static multiple fault strategy is strictly related to the structure of the system, and that the use of an on-line multiple fault strategy can diagnose faults in systems with as many as 10,000 failure sources.

Shakeri, M.↗

NASA NTRS1997

Multiple Fault Isolation in Redundant Systems

We consider the problem of sequencing tests to isolate multiple faults in redundant (fault-tolerant) systems with minimum expected testing cost (time). It can be shown that single faults and minimal faults, i.e., minimum number of failures with a failure signature different from the union of failure signatures of individual failures, together with their failure signatures, constitute the necessary information for fault diagnosis in redundant systems. In this paper, we develop an algorithm to find all the minimal faults and their failure signatures. Then, we extend the Sure diagnostic strategies [1] of our previous work to diagnose multiple faults in redundant systems. The proposed algorithms and strategies are illustrated using several examples.

Shakeri, M.↗

NASA NTRS1997

Sequential Testing Algorithms for Multiple Fault Diagnosis

In this paper, we consider the problem of constructing optimal and near-optimal test sequencing algorithms for multiple fault diagnosis. The computational complexity of solving the optimal multiple-fault isolation problem is super-exponential, that is, it is much more difficult than the single-fault isolation problem, which, by itself, is NP-hard. By employing concepts from information theory and AND/OR graph search, we present several test sequencing algorithms for the multiple fault isolation problem. These algorithms provide a trade-off between the degree of suboptimality and computational complexity. Furthermore, we present novel diagnostic strategies that generate a diagnostic directed graph (digraph), instead of a diagnostic tree, for multiple fault diagnosis. Using this approach, the storage complexity of the overall diagnostic strategy reduces substantially. The algorithms developed herein have been successfully applied to several real-world systems. Computational results indicate that the size of a multiple fault strategy is strictly related to the structure of the system.

Shakeri, Mojdeh↗

NASA NTRS1997

Algorithms for Multiple Fault Diagnosis With Unreliable Tests

In this paper, we consider the problem of constructing optimal and near-optimal multiple fault diagnosis (MFD) in bipartite systems with unreliable (imperfect) tests. It is known that exact computation of conditional probabilities for multiple fault diagnosis is NP-hard. The novel feature of our diagnostic algorithms is the use of Lagrangian relaxation and subgradient optimization methods to provide: (1) near optimal solutions for the MFD problem, and (2) upper bounds for an optimal branch-and-bound algorithm. The proposed method is illustrated using several examples. Computational results indicate that: (1) our algorithm has superior computational performance to the existing algorithms (approximately three orders of magnitude improvement), (2) the near optimal algorithm generates the most likely candidates with a very high accuracy, and (3) our algorithm can find the most likely candidates in systems with as many as 1000 faults.

Shakeri, Mojdeh↗

NASA NTRS1997

Multiple Fault Isolation in Redundant Systems

Fault diagnosis in large-scale systems that are products of modem technology present formidable challenges to manufacturers and users. This is due to large number of failure sources in such systems and the need to quickly isolate and rectify failures with minimal down time. In addition, for fault-tolerant systems and systems with infrequent opportunity for maintenance (e.g., Hubble telescope, space station), the assumption of at most a single fault in the system is unrealistic. In this project, we have developed novel block and sequential diagnostic strategies to isolate multiple faults in the shortest possible time without making the unrealistic single fault assumption.

Pattipati, Krishna R.↗