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Towards Prognostics of Electrolytic Capacitors

A remaining useful life prediction algorithm and degradation model for electrolytic capacitors is presented. Electrolytic capacitors are used in several applications ranging from power supplies on critical avionics equipment to power drivers for electro-mechanical actuators. These devices are known for their low reliability and given their criticality in electronics subsystems they are a good candidate for component level prognostics and health management research. Prognostics provides a way to assess remaining useful life of a capacitor based on its current state of health and its anticipated future usage and operational conditions. In particular, experimental results of an accelerated aging test under electrical stresses are presented. The capacitors used in this test form the basis for a remaining life prediction algorithm where a model of the degradation process is suggested. This preliminary remaining life prediction algorithm serves as a demonstration of how prognostics methodologies could be used for electrolytic capacitors.

Celaya, Jose R.

Physics Mining of Multi-Source Data Sets

Powerful new parallel data mining algorithms can produce diagnostic and prognostic numerical models and analyses from observational data. These techniques yield higher-resolution measures than ever before of environmental parameters by fusing synoptic imagery and time-series measurements. These techniques are general and relevant to observational data, including raster, vector, and scalar, and can be applied in all Earth- and environmental science domains. Because they can be highly automated and are parallel, they scale to large spatial domains and are well suited to change and gap detection. This makes it possible to analyze spatial and temporal gaps in information, and facilitates within-mission replanning to optimize the allocation of observational resources. The basis of the innovation is the extension of a recently developed set of algorithms packaged into MineTool to multi-variate time-series data. MineTool is unique in that it automates the various steps of the data mining process, thus making it amenable to autonomous analysis of large data sets. Unlike techniques such as Artificial Neural Nets, which yield a blackbox solution, MineTool's outcome is always an analytical model in parametric form that expresses the output in terms of the input variables. This has the advantage that the derived equation can then be used to gain insight into the physical relevance and relative importance of the parameters and coefficients in the model. This is referred to as physics-mining of data. The capabilities of MineTool are extended to include both supervised and unsupervised algorithms, handle multi-type data sets, and parallelize it.

Helly, John

Development of an On-board Failure Diagnostics and Prognostics System for Solid Rocket Booster

We develop a case breach model for the on-board fault diagnostics and prognostics system for subscale solid-rocket boosters (SRBs). The model development was motivated by recent ground firing tests, in which a deviation of measured time-traces from the predicted time-series was observed. A modified model takes into account the nozzle ablation, including the effect of roughness of the nozzle surface, the geometry of the fault, and erosion and burning of the walls of the hole in the metal case. The derived low-dimensional performance model (LDPM) of the fault can reproduce the observed time-series data very well. To verify the performance of the LDPM we build a FLUENT model of the case breach fault and demonstrate a good agreement between theoretical predictions based on the analytical solution of the model equations and the results of the FLUENT simulations. We then incorporate the derived LDPM into an inferential Bayesian framework and verify performance of the Bayesian algorithm for the diagnostics and prognostics of the case breach fault. It is shown that the obtained LDPM allows one to track parameters of the SRB during the flight in real time, to diagnose case breach fault, and to predict its values in the future. The application of the method to fault diagnostics and prognostics (FD&P) of other SRB faults modes is discussed.

Smelyanskiy, Vadim N.

Hybrid Model Based Approaches for Systems Health Management and Prognostics

This is a previously approved and published presentation. To accurately predict the future state of any system, it is required to possess knowledge of its current health state and future operational conditions. Present achievements of data-driven algorithms in regression of complex nonlinear functions and classification tasks have generated a growing interest in artificial intelligence for industrial applications. Complex multi-physics models as well as digital twins, once purely built on physics and corresponding simplified lumped parameter iterations, can now benefit from machine learning algorithms to mitigate the lack of understanding of some complex behavior. Given models of the current and future system behavior, a general approach of model-based prognostics can solve the prediction problem and further decision-making. In principle, data-driven approaches can replace expensive experimental test-setups as well as reduce the number of simulations needed to explore, e.g., the parametric space of a multi-parameter model. Nonetheless, the limitations of pure data-driven methods came to light rather quickly, at least for some industries. In many industrial applications, data acquisition is costly, and the volume of data that can be collected does not satisfy the requirements for effective model training and cross-validation. Therefore, some recent works in the area of machine learning is focusing on blending physics with data-driven algorithms, thus mitigating the drawbacks of the two approaches and emphasizing respective advantages. Partial physical knowledge of the problem can aid the learning process by “guiding” the algorithm towards efficient solutions that satisfy the physics driving the system behavior. The result is a hybrid modeling approach combining physical knowledge as well data-driven methods to develop a unified hybrid approach. A hybrid framework for fusing information from physics-based performance models along with deep learning algorithms for prognostics of complex safety-critical systems is presented. In this framework, physics-based performance models infer unobservable model parameters related to the system's components health solving a calibration problem in the deep learning approach.

Prognostics

NASA Tech Briefs, July 2003

Topics covered include: Real-Time, High-Frequency QRS Electrocardiograph; Software for Improved Extraction of Data From Tape Storage; Radio System for Locating Emergency Workers; Software for Displaying High-Frequency Test Data; Capacitor-Chain Successive-Approximation ADC; Simpler Alternative to an Optimum FQPSK-B Viterbi Receiver; Multilayer Patch Antenna Surrounded by a Metallic Wall; Software To Secure Distributed Propulsion Simulations; Explicit Pore Pressure Material Model in Carbon-Cloth Phenolic; Meshed-Pumpkin Super-Pressure Balloon Design; Corrosion Inhibitors as Penetrant Dyes for Radiography; Transparent Metal-Salt-Filled Polymeric Radiation Shields; Lightweight Energy Absorbers for Blast Containers; Brush-Wheel Samplers for Planetary Exploration; Dry Process for Making Polyimide/ Carbon-and-Boron-Fiber Tape; Relatively Inexpensive Rapid Prototyping of Small Parts; Magnetic Field Would Reduce Electron Backstreaming in Ion Thrusters; Alternative Electrochemical Systems for Ozonation of Water; Interferometer for Measuring Displacement to Within 20 pm; UV-Enhanced IR Raman System for Identifying Biohazards; Prognostics Methodology for Complex Systems; Algorithms for Haptic Rendering of 3D Objects; Modeling and Control of Aerothermoelastic Effects; Processing Digital Imagery to Enhance Perceptions of Realism; Analysis of Designs of Space Laboratories; Shields for Enhanced Protection Against High-Speed Debris; Study of Dislocation-Ordered In(x)Ga(1-x)As/GaAs Quantum Dots; and Tilt-Sensitivity Analysis for Space Telescopes.

Source record

Hybrid Model Based Approaches for Systems Health Management and Prognostics

To facilitate and solve the prediction problem, awareness of the current health state of the system is key, since it is necessary to perform condition-based predictions. To accurately predict the future state of any system, it is required to possess knowledge of its current health state and future operational conditions. Latest achievements of data-driven algorithms in regression of complex nonlinear functions and classification tasks have generated a growing interest in artificial intelligence for industrial applications. Complex multi-physics models as well as digital twins, once purely built on physics and corresponding simplified lumped parameter iterations, can now benefit from machine learning algorithms to mitigate the lack of understanding of some complex behavior. Given models of the current and future system behavior, a general approach of model-based prognostics can solve the prediction problem and further decision making. In principle, data driven approaches can replace expensive experimental test-setups as well as reduce the number of simulations needed to explore, e.g., the parametric space of a multi-parameter model. Nonetheless, the limitations of pure data-driven methods came to light rather quickly, at least for some industries. In many industrial applications, data acquisition is costly, and the volume of data that can be collected does not satisfy the requirements for an effective model training and cross-validation. Therefore, some recent works in the area of machine learning is focusing on blending physics with data-driven algorithms, thus mitigating the drawbacks of the two approaches and emphasizing respective advantages. Partial physical knowledge of the problem can aid the learning process by “guiding” the algorithm towards efficient solutions that satisfy the physics driving the system behavior. The result is a hybrid modeling approach combining physical knowledge as well data driven methods to develop a unified hybrid approach. A hybrid framework for fusing information from physics-based performance models along with deep learning algorithms for prognostics of complex safety critical systems is presented. In this framework, physics-based performance models infer unobservable model parameters related to the system's components health solving a calibration problem in the deep learning approach.

Hybrid Modeling

Hybrid Approaches to Systems Health Management and Prognostics

To facilitate and solve the prediction problem, awareness of the current health state of the system is key, since it is necessary to perform condition-based predictions. To accurately predict the future state of any system, it is required to possess knowledge of its current health state and future operational conditions. Latest achievements of data-driven algorithms in regression of complex nonlinear functions and classification tasks have generated a growing interest in artificial intelligence for industrial applications. Complex multi-physics models as well as digital twins, once purely built on physics and corresponding simplified lumped parameter iterations, can now benefit from machine learning algorithms to mitigate the lack of understanding of some complex behavior. Given models of the current and future system behavior, a general approach of model-based prognostics can solve the prediction problem and further decision making. In principle, data driven approaches can replace expensive experimental test-setups as well as reduce the number of simulations needed to explore, e.g., the parametric space of a multi-parameter model. Nonetheless, the limitations of pure data-driven methods came to light rather quickly, at least for some industries. In many industrial applications, data acquisition is costly, and the volume of data that can be collected does not satisfy the requirements for an effective model training and cross-validation. Therefore, some recent works in the area of machine learning is focusing on blending physics with data-driven algorithms, thus mitigating the drawbacks of the two approaches and emphasizing respective advantages. Partial physical knowledge of the problem can aid the learning process by “guiding” the algorithm towards efficient solutions that satisfy the physics driving the system behavior. The result is a hybrid modeling approach combining physical knowledge as well data driven methods to develop a unified hybrid approach. A hybrid framework for fusing information from physics-based performance models along with deep learning algorithms for prognostics of complex safety critical systems is presented. In this framework, physics-based performance models infer unobservable model parameters related to the system's components health solving a calibration problem in the deep learning approach.

Systems Health Management

A Prognostics Framework Development for Swarm Satellite Formations

Prognostics is the science of predicting the failure(s) of a component or a system and understanding how the performance will change in the event of a failure or degradation mechanism. With accurate predictions of possible failures, autonomous mitigative actions can be taken to correct/repair any issues or alert human operators of a failure threshold exceedance requiring condition-based maintenance. Although there is extensive research on failure predictions for a component or a system, there are significantly more opportunities to foray into failure predictions and prognostics for a system of systems such as an airspace consisting of multiple aircraft, a fleet of unmanned aerial vehicles, and a swarm of intelligent satellite systems. Failure prediction and mitigation are particularly important in autonomous systems such as satellite swarm systems that need effective resource management and minimal human interactions. Based on NASA's decadal survey, there is a clear need to prioritize the development of satellite swarm technology for studies of space physics and Earth science. The science community will propose future missions that return in-situ measurements from a 3-D (three-dimensional) volume of space, with relative spacecraft motion and inter-satellite baselines controlled according to the mission objectives. For such multi-spacecraft missions, it is required that ground operations resources do not scale with the number of satellites, thus compromising the swarm or leading to inefficiencies in resource allocation. Swarms of tens or hundreds of small satellites will require autonomy in attitude control, navigation and failure. Although significant research has been conducted in the areas of autonomous formation flying algorithms, less attention has been given to the development of resilient systems robust to failures.The focus of this research paper is the integration of model-based prognostics into the swarm dynamics control and decision-making algorithms. We simulate swarm management strategies for a subsystem failure to demonstrate the importance of failure predictions by comparing two cases: (i) no health information is provided to the system and utilized in the decision-making process and (2) system health information is obtained using prognostics and employed by the control system. One example scenario presented is for the GPS (Global Positioning System) system of an individual satellite to perform off-nominally due to increasing estimated error. In this scenario, the keep-out zone for that satellite would become more conservative, thereby decreasing the risk of collision. This is achieved via tuning the individual artificial repulsive functions assigned to each satellite.This paper is structured as follows. First we provide an overview of current swarm technology development, where we specifically use the term swarm to define multiple satellites flying in formation in similar orbits, with cross-link communication and station-keeping capabilities. Second, we give an introduction to the Swarm Orbital Dynamics Advisor (SODA), a tool that accepts high-level configuration commands and provides the orbital maneuvers required to achieve the prescribed formation configuration. Third, we provide the details of the model-based prognostics algorithm implementation in SODA. Finally, we present different case studies for potential component/subsystem failures and the swarm responses based with and without failure prediction information.

prognostics

Dynamic Adjustment of Simulation Parameters for Efficient Vehicle Prognostics

Model-based diagnostics and prognostics rely on state estimation and uncertainty management algorithms to produce useful information for system operators and maintainers. This information enables more informed operational decisions, condition-based maintenance, and overall mission safety assurance. Typically, uncertainty is associated with vehicle state-of-health estimation and prediction results because of modeling errors, internal or external sources of noise, and sensor inaccuracy. Probabilistic uncertainty management methods including Sequential Monte Carlo simulation are commonly used to reason about state-of-health estimates and predictions in the presence of these sources of uncertainty. However, such algorithms can be computationally expensive as they require a very large number of samples to obtain a sufficiently accurate quantification of the end of life probability distribution. As a result, highly mobile autonomous systems that leverage the prognostic results for mission-level replanning are often constrained in their processing capability because of these computationally expensive simulation approaches. Therefore, in this paper, we investigate algorithmic methods for dynamically adjusting simulation time step as well as number of samples to achieve highly efficient prognostic results while maintaining results accuracy. Results obtained from simulated flight experiments of an electric unmanned aerial vehicle are presented to verify the efficacy of such algorithms.

Prognostics

A High-Performance Computing Predictive GNSS Performance Monitor for Autonomous Air Vehicles in Urban Environments

This report offers analysis and design insights for leveraging High-Performance Computing (HPC) to predict line-of-sight (LOS) Global Navigation Satellite System (GNSS) availability in a city. This work is motivated by the emerging fields of Advanced and Urban Air Mobility (AAM/UAM), where regulatory authorities are seeking city-scale, meter-resolution risk forecasting in order to safely integrate new flight missions with existing urban life and infrastructure. This work addresses the technical challenge of efficiently computing urban GNSS satellite visibility to predict GNSS performance metrics under these requirements. We present a new HPC-optimized shadow casting algorithm variant as a ray-based approach to forecasting satellite visibility. We apply this algorithm variant in a software-defined prognostic service which generates a GNSS navigation risk-correlated map as a path planning-style potential field. We detail dominant computational burdens, viable simplifying assumptions, and different algorithmic implementations, intending to demonstrate a baseline of computation time needed by each stage in such a service. We conclude by analyzing the prototype service’s prediction accuracy compared to receiver data from Corpus Christi, Texas. This informs design trade-offs along the dimensions of hardware, computation time, and tolerable forecasting error (including proportions of false positives and false negatives).

GNSS

An On-Board Off-Board Framework for Online Replanning: Applied to UAVs in Urban Environments

Autonomous systems are being used in a multitude of areas at an increasing rate and require a high level of adaptivity and intelligence to operate safely, especially under faulty conditions. This paper introduces a novel genetic algorithm tailored for UAV trajectory replanning, with an improved execution time via search space reduction based on the operating conditions of the UAV and its remaining mission. A unique characteristic of the replanning agent is its fast-start and adaptive properties, pre-seeding candidates with partial solutions and dynamically tuning elitism, crossover, and mutation rates in correspondence to the average fitness and diversity of the population. A population restart mechanism and early stopping mechanism are evaluated as well to assess their effect on solution quality and runtime. Previous work on genetic algorithms for UAV replanning were conducted with short trajectories in a small state space. Our UAV operates in a 56,000 square meter simulated urban environment, with static obstacles and a total of 53 possible waypoints. The agent increases the safety and reliability of UAV autonomy when operating under faulty conditions and when replanning is required.

Machine Learning

Prognostics for Systems Health Management - Model and Hybrid Based Approaches. Where are We Heading?

To facilitate and solve the prediction problem, awareness of the current state and health of the system is key, since it is necessary to perform condition-based system health predictions. To accurately predict the future state of any system, it is required to possess knowledge of its current health state and future operational conditional. In case of next generation electric aircrafts, computing remaining flying time is safety-critical, since an aircraft that runs out of power (battery charge) while in the air will eventually lose control leading to catastrophe. In order to tackle and solve the prediction problem, it is essential to have awareness of the current health state of the system, especially since it is necessary to perform condition-based predictions. To be able to predict the future state of the system, it is also required to possess knowledge of the current and future operational conditions and flight profiles for accurate estimation of end-of-discharge (EOD) for the batteries. Similar framework can be implemented to other complex systems and subsystems. Our research approach is to develop a system level health monitoring safety indicator which runs estimation and prediction algorithms to estimate remaining useful life predictions at system, subsystem swell as component levels. Given models of the current and future system behavior, a general approach of model-based prognostics is discussed as a solution to the prediction problem and further for decision making. Data driven prognostics approaches have been equally used with good results in the past, where respective approaches have their own challenges to tackle. This limits their applicability to complex real-world domains: (a) high complexity or incompleteness of physics-based models and (b) limited representativeness of the training dataset for data-driven models. With the advent of internet of things for data collection and increased use of ML algorithms, hybrid approaches are the next avenue to reduce the challenges and achieve better results. An hybrid framework for fusing information from physics-based performance models along with deep learning algorithms for prognostics of complex safety critical systems is presented. In this framework, we use physics-based performance models to infer unobservable model parameters related to the system's components health solving a calibration problem.

Prognostics

Towards A Model-Based Prognostics Methodology for Electrolytic Capacitors: A Case Study Based on Electrical Overstress Accelerated Aging

A remaining useful life prediction methodology for electrolytic capacitors is presented. This methodology is based on the Kalman filter framework and an empirical degradation model. Electrolytic capacitors are used in several applications ranging from power supplies on critical avionics equipment to power drivers for electro-mechanical actuators. These devices are known for their comparatively low reliability and given their criticality in electronics subsystems they are a good candidate for component level prognostics and health management. Prognostics provides a way to assess remaining useful life of a capacitor based on its current state of health and its anticipated future usage and operational conditions. We present here also, experimental results of an accelerated aging test under electrical stresses. The data obtained in this test form the basis for a remaining life prediction algorithm where a model of the degradation process is suggested. This preliminary remaining life prediction algorithm serves as a demonstration of how prognostics methodologies could be used for electrolytic capacitors. In addition, the use degradation progression data from accelerated aging, provides an avenue for validation of applications of the Kalman filter based prognostics methods typically used for remaining useful life predictions in other applications.

Celaya, Jose R.

A Model-based Prognostics Methodology for Electrolytic Capacitors Based on Electrical Overstress Accelerated Aging

A remaining useful life prediction methodology for electrolytic capacitors is presented. This methodology is based on the Kalman filter framework and an empirical degradation model. Electrolytic capacitors are used in several applications ranging from power supplies on critical avionics equipment to power drivers for electro-mechanical actuators. These devices are known for their comparatively low reliability and given their criticality in electronics subsystems they are a good candidate for component level prognostics and health management. Prognostics provides a way to assess remaining useful life of a capacitor based on its current state of health and its anticipated future usage and operational conditions. We present here also, experimental results of an accelerated aging test under electrical stresses. The data obtained in this test form the basis for a remaining life prediction algorithm where a model of the degradation process is suggested. This preliminary remaining life prediction algorithm serves as a demonstration of how prognostics methodologies could be used for electrolytic capacitors. In addition, the use degradation progression data from accelerated aging, provides an avenue for validation of applications of the Kalman filter based prognostics methods typically used for remaining useful life predictions in other applications.

Electrolytic capacitors

Distributed Prognostics based on Structural Model Decomposition

Within systems health management, prognostics focuses on predicting the remaining useful life of a system. In the model-based prognostics paradigm, physics-based models are constructed that describe the operation of a system and how it fails. Such approaches consist of an estimation phase, in which the health state of the system is first identified, and a prediction phase, in which the health state is projected forward in time to determine the end of life. Centralized solutions to these problems are often computationally expensive, do not scale well as the size of the system grows, and introduce a single point of failure. In this paper, we propose a novel distributed model-based prognostics scheme that formally describes how to decompose both the estimation and prediction problems into independent local subproblems whose solutions may be easily composed into a global solution. The decomposition of the prognostics problem is achieved through structural decomposition of the underlying models. The decomposition algorithm creates from the global system model a set of local submodels suitable for prognostics. Independent local estimation and prediction problems are formed based on these local submodels, resulting in a scalable distributed prognostics approach that allows the local subproblems to be solved in parallel, thus offering increases in computational efficiency. Using a centrifugal pump as a case study, we perform a number of simulation-based experiments to demonstrate the distributed approach, compare the performance with a centralized approach, and establish its scalability. Index Terms-model-based prognostics, distributed prognostics, structural model decomposition ABBREVIATIONS

centrifugal pump

Model-Based Prognostics

This tutorial will cover the basics of model-based prognostics, and include concepts such as modeling approaches, estimation and prediction algorithms, and how uncertainty is represented and quantified. Other topics covered will include structural model decomposition, system-level prognostics, prognostics of hybrid systems, and distributed prognostics. Several case studies, such as water recovery systems to the prediction of safety margins in the national airspace system will be used to explain different concepts of prognostics and demonstrate their application to real-world systems.

Roychoudhury, Indranil

A Generic Software Architecture For Prognostics

Prognostics is a systems engineering discipline focused on predicting end-of-life of components and systems. As a relatively new and emerging technology, there are few fielded implementations of prognostics, due in part to practitioners perceiving a large hurdle in developing the models, algorithms, architecture, and integration pieces. As a result, no open software frameworks for applying prognostics currently exist. This paper introduces the Generic Software Architecture for Prognostics (GSAP), an open-source, cross-platform, object-oriented software framework and support library for creating prognostics applications. GSAP was designed to make prognostics more accessible and enable faster adoption and implementation by industry, by reducing the effort and investment required to develop, test, and deploy prognostics. This paper describes the requirements, design, and testing of GSAP. Additionally, a detailed case study involving battery prognostics demonstrates its use.

Software Framework

A Generic Software Architecture for Prognostics

Prognostics is a systems engineering discipline focused on predicting end-of-life of components and systems. As a relatively new and emerging technology, there are few fielded implementations of prognostics, due in part to practitioners perceiving a large hurdle in developing the models, algorithms, architecture, and integration pieces. As a result, no open software frameworks for applying prognostics currently exist. This paper introduces the Generic Software Architecture for Prognostics (GSAP), an open-source, cross-platform, object-oriented software framework and support library for creating prognostics applications. GSAP was designed to make prognostics more accessible and enable faster adoption and implementation by industry, by reducing the effort and investment required to develop, test, and deploy prognostics. This paper describes the requirements, design, and testing of GSAP. Additionally, a detailed case study involving battery prognostics demonstrates its use.

Prognostics and Health Management (PHM)