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All sources NASA NTRS DOE OSTI

DOE OSTI2023

Long–short-term memory encoder–decoder with regularized hidden dynamics for fault detection in industrial processes

The ability of recurrent neural networks (RNN) to model nonlinear dynamics of high dimensional process data has enabled data-driven RNN-based fault detection algorithms. Previous studies have focused on detecting faults by identifying the discrepancies in data distribution between the faulty and normal data, as reflected in prediction errors generated by RNN models. However, in industrial processes, variations in data distribution can also result from changes in normal control setpoints and compensatory control adjustments in response to disturbances, making it hard to differentiate between normal and faulty conditions. This paper proposes a fault detection method utilizing a long short-term memory (LSTM) encoder–decoder structure with regularized hidden dynamics and reversible instance normalization (RevIN) to compactly represent high-dimensional measurements for effective monitoring. During training, the hidden states of the model are regularized to form a low-dimensional latent space representation of the original multivariate time series data. As a result, the prediction errors of the latent states can be used to monitor the abnormal dynamic variations, while the reconstruction errors of the measured variables are used to monitor the abnormal static variations. Furthermore, the proposed indices can reflect operating conditions, even when the distribution of test data changes, which helps distinguish faults from normal adjustments and disturbances that controllers can settle. Here, data from numerical simulation and the Tennessee Eastman process are used to illustrate the effectiveness of the proposed fault detection method.

42 ENGINEERING↗

NASA NTRS2009

A Mode-Shape-Based Fault Detection Methodology for Cantilever Beams

An important goal of NASA's Internal Vehicle Health Management program (IVHM) is to develop and verify methods and technologies for fault detection in critical airframe structures. A particularly promising new technology under development at NASA Langley Research Center is distributed Bragg fiber optic strain sensors. These sensors can be embedded in, for instance, aircraft wings to continuously monitor surface strain during flight. Strain information can then be used in conjunction with well-known vibrational techniques to detect faults due to changes in the wing's physical parameters or to the presence of incipient cracks. To verify the benefits of this technology, the Formal Methods Group at NASA LaRC has proposed the use of formal verification tools such as PVS. The verification process, however, requires knowledge of the physics and mathematics of the vibrational techniques and a clear understanding of the particular fault detection methodology. This report presents a succinct review of the physical principles behind the modeling of vibrating structures such as cantilever beams (the natural model of a wing). It also reviews two different classes of fault detection techniques and proposes a particular detection method for cracks in wings, which is amenable to formal verification. A prototype implementation of these methods using Matlab scripts is also described and is related to the fundamental theoretical concepts.

Tejada, Arturo↗

DOE OSTI2023

Automated fault detection and diagnosis of airflow and refrigerant charge faults in residential HVAC systems using IoT-enabled measurements

While automated fault detection and diagnosis (AFDD) in residential heating, ventilation, and air-conditioning (HVAC) using smart thermostat data is gaining increasing attention in recent times, it still requires in-depth investigation for market adoption, especially with real-life data. Furthermore, this paper proposes an Internet of Things (IoT) - based approach that adds a smart sensor to the smart thermostat data to carry out AFDD. The approach uses a model which predicts enthalpy change across the evaporator and compares the prediction to the measured enthalpy change. Deviations which exceed analytically determined thresholds then signal faults in the HVAC system. The faults detected are either installation related or degradation related. Experimental tests were carried out in four homes located in Norman, Oklahoma. From the tests, installation issues like indoor/outdoor mismatch were detected in two homes, while a 30% low charge and low indoor airflow rate were detected in one home. The results show that the proposed AFDD algorithm was able to successfully detect two prevalent faults, namely low indoor airflow and low refrigerant charge. Unlike most of the smart thermostat-based approaches, the proposed IoT-based approach can detect and diagnose both faults but only require one additional sensor which is provided by smart thermostat manufacturers.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Curation of Ground-Truth Validated Benchmarking Datasets for Fault Detection & Diagnostics Tools

Fault detection and diagnostics (FDD) analytical tools for heating, ventilation and air conditioning (HVAC) systems represent one of the most active areas of smart building technology development. A diversity of techniques is used for FDD analytics, spanning physical models, black box, and rule-based approaches, and researchers continuously strive to develop improved algorithms. With FDD algorithm numbers now in the hundreds, there is a need for performance evaluation of these algorithms in order to assess improvements, improve costeffectiveness, and to prioritize investment in the further development of these technologies. A persistent challenge of FDD advance has been the lack of common datasets to benchmark the performance accuracy of FDD algorithms. This paper summarizes the successful curation of HVAC operational data, paired with validated ground-truth information regarding the presence and absence of faults. The current dataset, consisting of both simulation and experimental data, will evolve to include a larger set of HVAC systems with the objective of creating the largest publicly available dataset to be used by FDD developers, users, and researchers to compare and contrast performance accuracy across FDD algorithms, helping to drive improvements that will spur greater market adoption of FDD tools. Furthermore, in order to avoid previously observed issues with contributed datasets and ensure high quality and consistency of future submissions, the development of data validation and ground-truth assessment protocol is detailed in this study.

Casillas, Armando↗

DOE OSTI2019

Bearing Fault Detection and Wear Estimation Using Machine Learning

Unpredicted bearings failures can be costly and dangerous. Current methods have been examining the use of machine learning algorithms to automatically detect bearing faults. Vibration specialists must react daily, as the sheer number of bearings and the machines they operate are critical and any downtime will result in loss of productivity and endanger personal. The method presented in this paper utilizes a novel approach to detect and determine bearings fault diameters. The detection algorithm uses the cubic support vector machine (SVM) for high accuracy inner and outer race fault detection. After detecting the type of fault, the data is then passed through a second layer that uses a modified K-means clustering and a linear interpolation to accurately estimate the diameter of the fault that was detected.

42 ENGINEERING↗

DOE OSTI2023

Early Fault Detection in Particle Accelerator Power Electronics Using Ensemble Learning

Early fault detection and fault prognosis are crucial to ensure efficient and safe operations of complex engineering systems such as the Spallation Neutron Source (SNS) and its power electronics (high voltage converter modulators). Following an advanced experimental facility setup that mimics SNS operating conditions, the authors successfully conducted 21 early fault detection experiments, where fault precursors are introduced in the system to a degree enough to cause degradation in the waveform signals, but not enough to reach a real fault. Nine different machine learning techniques based on ensemble trees, convolutional neural networks, support vector machines, and hierarchical voting ensembles are proposed to detect the fault precursors. Although all 9 models have shown a perfect and identical performance during the training and testing phase, the performance of most models has decreased in the next test phase once they got exposed to realworld data from the 21 experiments. The hierarchical voting ensemble, which features multiple layers of diverse models, maintains a distinguished performance in early detection of the fault precursors with 95% success rate (20/21 tests), followed by adaboost and extremely randomized trees with 52% and 48% success rates, respectively. The support vector machine models were the worst with only 24% success rate (5/21 tests). The study concluded that a successful implementation of machine learning in the SNS or particle accelerator power systems would require a major upgrade in the controller and the data acquisition system to facilitate streaming and handling big data for the machine learning models. In addition, this study shows that the best performing models were diverse and based on the ensemble concept to reduce the bias and hyperparameter sensitivity of individual models.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Toward Statistical Real-Time Power Fault Detection

We propose statistical fault detection methodology based on high-frequency data streams that are becoming available in modern power grids. Our approach can be treated as an online (sequential) change point monitoring methodology. However, due to the mostly unexplored and very nonstandard structure of high-frequency power grid streaming data, substantial new statistical development is required to make this methodology practically applicable. The paper includes development of scalar detectors based on multichannel data streams, determination of data-driven alarm thresholds and investigation of the performance and robustness of the new tools. Due to a reasonably large database of faults, we can calculate frequencies of false and correct fault signals, and recommend implementations that optimize these empirical success rates.

bolted faults↗

DOE OSTI2023

High Impedance Fault Detection Through Quasi-Static State Estimation: A Parameter Error Modeling Approach

This paper presents a model for detecting high impedance faults using parameter error modeling and a two step per-phase weighted-least squares state estimation process. The proposed scheme leverages the use of Phasor Measurement Units and synthetic measurements to identify per-phase power flow and injection measurements which indicate a parameter error through ?2 Hypothesis Testing applied to the composed measurement error. Although current and voltage waveforms are commonly analyzed for high-impedance fault detection, wide area power flow and injection measurements, which are already inherent to the state estimation process, also show promise for real-world high-impedance fault detection applications. The error distributions after detection share the measurement function error spread observed in proven parameter error diagnostics and can be applied to high-impedance fault identification. Further, this error spread across measurement functions related to the fault will be clearly discerned from measurement error. Case studies are performed on the IEEE 33-Bus Distribution System along with the proposed model in Simulink.

Cooper, Austin↗

DOE OSTI2015

Final Technical Report: PV Fault Detection Tool.

The PV Fault Detection Tool project plans to demonstrate that the FDT can (a) detect catastrophic and degradation faults and (b) identify the type of fault. This will be accomplished by collecting fault signatures using different instruments and integrating this information to establish a logical controller for detecting, diagnosing and classifying each fault.

42 ENGINEERING↗

DOE OSTI2022

Node Monitoring as a Fault Detection Countermeasure against Information Leakage within a RISC-V Microprocessor

Advanced, superscalar microprocessors (μP) are highly susceptible to wear-out failures because of their highly complex, densely packed circuit structure and extreme operational frequencies. Although many types of fault detection and mitigation strategies have been proposed, none have addressed the specific problem of detecting faults that lead to information leakage events on I/O channels of the μP. Information leakage can be defined very generally as any type of output that the executing program did not intend to produce. In this work, we restrict this definition to output that represents a security concern, and in particular, to the leakage of plaintext or encryption keys, and propose a counter-based countermeasure to detect faults that cause this type of leakage event. Fault injection (FI) experiments are carried out on two RISC-V microprocessors emulated as soft cores on a Xilinx multi-processor System-on-chip (MPSoC) FPGA. The μP designs are instrumented with a set of counters that records the number of transitions that occur on internal nodes. The transition counts are collected from all internal nodes under both fault-free and faulty conditions, and are analyzed to determine which counters provide the highest fault coverage and lowest latency for detecting leakage faults. We show that complete coverage of all leakage faults is possible using only a single counter strategically placed within the branch compare logic of the μPs.

42 ENGINEERING↗

DOE OSTI2023

1-D Convolutional Graph Convolutional Networks for Fault Detection in Distributed Energy Systems

This paper presents a 1-D convolutional and graph convolutional networks for fault detection in microgrids. The combination of 1-D convolutional neural networks (1D-CNN) and graph convolutional networks (GCN) helps extract both spatial-temporal correlations from the voltage measurements in microgrids. The fault detection scheme includes fault event detection, fault type and phase classification, and fault location. There are five neural network model training to handle these tasks. Transfer learning and fine-tuning are applied to reduce training efforts. The combined 1-D convolutional and graph convolutional networks (1D-CGCN) is compared with the traditional ANN structure on the Potsdam 13-bus microgrid dataset. The accuracy of 99.5%, 98.4%, 99.2%, and 95.5% are achieved in fault event detection, fault type classification, fault phase identification, and fault location respectively. The detailed confusion matrices of fault type and fault phase classification are provided for validation.

deep neural network↗

DOE OSTI2021

Fault Detection on Seismic Structural Images Using a Nested Residual U-Net

Automatic identification of faults on seismic structural images is a challenging yet crucial task in quantitative seismic interpretation. Human picking or attribute-based fault detection methods may misidentify faults on noisy, complex seismic images. In this work, we develop a new automatic fault detection method using a nested residual U-shaped convolutional neural network. Each of the encoders and decoders in this neural network is a residual U-Net, leading to a nested architecture. The final fault map results from the fusion of three fault maps with low, medium, and high fault resolutions. We demonstrate the excellent fault-detection capability of our nested neural network using a series of synthetic and field seismic images. We find that our approach produces clearer and more interpretable fault maps than the current state-of-the-art U-Net fault detection method, particularly on noisy seismic images. Our new automatic fault detection method can facilitate reliable quantitative seismic interpretation on field seismic images.

58 GEOSCIENCES↗

DOE OSTI2019

A performance evaluation framework for building fault detection and diagnosis algorithms

Fault detection and diagnosis (FDD) algorithms for building systems and equipment represent one of the most active areas of research and commercial product development in the buildings industry. However, far more effort has gone into developing these algorithms than into assessing their performance. As a result, considerable uncertainties remain regarding the accuracy and effectiveness of both research-grade FDD algorithms and commercial products - a state of affairs that has hindered the broad adoption of FDD tools. This article presents a general, systematic framework for evaluating the performance of FDD algorithms. The article focuses on understanding the possible answers to two key questions: in the context of FDD algorithm evaluation, what defines a fault and what defines an evaluation input sample? The answers to these questions, together with appropriate performance metrics, may be used to fully specify evaluation procedures for FDD algorithms.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Image-based novel fault detection with deep learning classifiers using hierarchical labels

One important characteristic of modern fault classification systems is the ability to flag the system when faced with previously unseen fault types. This work considers the unknown fault detection capabilities of deep neural network-based fault classifiers. Specifically, we propose a methodology on how, when available, labels regarding the fault taxonomy can be used to increase unknown fault detection performance without sacrificing model performance. To achieve this, we propose to utilize soft label techniques to improve the state-of-the-art deep novel fault detection techniques during the training process and novel hierarchically consistent detection statistics for online novel fault detection. Lastly, we demonstrated increased detection performance on novel fault detection in inspection images from the hot steel rolling process, with results well replicated across multiple scenarios and baseline detection methods.

42 ENGINEERING↗

DOE OSTI2018

The Fault Detection, Localization, and Tolerant Operation of Modular Multilevel Converters with an Insulated Gate Bipolar Transistor (IGBT) Open Circuit Fault

Reliability is one of the critical issues for a modular multilevel converter (MMC) since it consists of a large number of series-connected power electronics submodules (SMs). Here in this paper, a complete control strategy including fault detection, localization, and tolerant operation is proposed for the MMC under an insulated gate bipolar transistor (IGBT) open circuit fault. According to the output characteristics of the SM with the open-circuit fault of IGBT, a fault detection method based on the circulating current and output current observation is used. In order to further precisely locate the position of the faulty SM, a fault localization method based on the SM capacitor voltage observation is developed. After the faulty SM is isolated, the continuous operation of the converter is ensured by adopting the fault-tolerant strategy based on the use of redundant modules. To verify the proposed fault detection, fault localization, and fault-tolerant operation strategies, a 900 kVA MMC system under the conditions of an IGBT open circuit is developed in the Matlab/Simulink platform. The capabilities of rapid detection, precise positioning, and fault-tolerant operation of the investigated detection and control algorithms are also demonstrated.

42 ENGINEERING↗

NASA NTRS2011

Planetary Gearbox Fault Detection Using Vibration Separation Techniques

Studies were performed to demonstrate the capability to detect planetary gear and bearing faults in helicopter main-rotor transmissions. The work supported the Operations Support and Sustainment (OSST) program with the U.S. Army Aviation Applied Technology Directorate (AATD) and Bell Helicopter Textron. Vibration data from the OH-58C planetary system were collected on a healthy transmission as well as with various seeded-fault components. Planetary fault detection algorithms were used with the collected data to evaluate fault detection effectiveness. Planet gear tooth cracks and spalls were detectable using the vibration separation techniques. Sun gear tooth cracks were not discernibly detectable from the vibration separation process. Sun gear tooth spall defects were detectable. Ring gear tooth cracks were only clearly detectable by accelerometers located near the crack location or directly across from the crack. Enveloping provided an effective method for planet bearing inner- and outer-race spalling fault detection.

Lewicki, David G.↗

NASA NTRS1989

Advanced power system protection and incipient fault detection and protection of spaceborne power systems

This research concentrated on the application of advanced signal processing, expert system, and digital technologies for the detection and control of low grade, incipient faults on spaceborne power systems. The researchers have considerable experience in the application of advanced digital technologies and the protection of terrestrial power systems. This experience was used in the current contracts to develop new approaches for protecting the electrical distribution system in spaceborne applications. The project was divided into three distinct areas: (1) investigate the applicability of fault detection algorithms developed for terrestrial power systems to the detection of faults in spaceborne systems; (2) investigate the digital hardware and architectures required to monitor and control spaceborne power systems with full capability to implement new detection and diagnostic algorithms; and (3) develop a real-time expert operating system for implementing diagnostic and protection algorithms. Significant progress has been made in each of the above areas. Several terrestrial fault detection algorithms were modified to better adapt to spaceborne power system environments. Several digital architectures were developed and evaluated in light of the fault detection algorithms.

Russell, B. Don↗

NASA NTRS2004

Optimal Sensor Allocation for Fault Detection and Isolation

Automatic fault diagnostic schemes rely on various types of sensors (e.g., temperature, pressure, vibration, etc) to measure the system parameters. Efficacy of a diagnostic scheme is largely dependent on the amount and quality of information available from these sensors. The reliability of sensors, as well as the weight, volume, power, and cost constraints, often makes it impractical to monitor a large number of system parameters. An optimized sensor allocation that maximizes the fault diagnosibility, subject to specified weight, volume, power, and cost constraints is required. Use of optimal sensor allocation strategies during the design phase can ensure better diagnostics at a reduced cost for a system incorporating a high degree of built-in testing. In this paper, we propose an approach that employs multiple fault diagnosis (MFD) and optimization techniques for optimal sensor placement for fault detection and isolation (FDI) in complex systems. Keywords: sensor allocation, multiple fault diagnosis, Lagrangian relaxation, approximate belief revision, multidimensional knapsack problem.

Azam, Mohammad↗