With the continuous increase in complexity and expense of industrial systems, there is less tolerance for performance degradation, productivity decrease, and safety hazards, which greatly necessitates to detect and identify any kinds of potential abnormalities and faults as early as possible and implement real-time fault-tolerant operation for minimizing performance degradation and avoiding dangerous situations. During the last four decades, fruitful results have been reported about fault diagnosis and fault-tolerant control methods and their applications in a variety of engineering systems. The three-part survey paper aims to give a comprehensive review of real-time fault diagnosis and fault-tolerant control, with particular attention on the results reported in the last decade. In this paper, fault diagnosis approaches and their applications are comprehensively reviewed from model- and signal-based perspectives, respectively.

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A Survey of Fault Diagnosis and Fault-Tolerant Techniques—Part I: Fault Diagnosis With Model-Based and Signal-Based Approaches

Statistics and Data Analysis in Geology

Fault diagnosis is vital in manufacturing system, since early detections on the emerging problem can save invaluable time and cost. With the development of smart manufacturing, the data-driven fault diagnosis becomes a hot topic. However, the traditional data-driven fault diagnosis methods rely on the features extracted by experts. The feature extraction process is an exhausted work and greatly impacts the final result. Deep learning (DL) provides an effective way to extract the features of raw data automatically. Convolutional neural network (CNN) is an effective DL method. In this study, a new CNN based on LeNet-5 is proposed for fault diagnosis. Through a conversion method converting signals into two-dimensional (2-D) images, the proposed method can extract the features of the converted 2-D images and eliminate the effect of handcrafted features. The proposed method which is tested on three famous datasets, including motor bearing dataset, self-priming centrifugal pump dataset, and axial piston hydraulic pump dataset, has achieved prediction accuracy of 99.79%, 99.481%, and 100%, respectively. The results have been compared with other DL and traditional methods, including adaptive deep CNN, sparse filter, deep belief network, and support vector machine. The comparisons show that the proposed CNN-based data-driven fault diagnosis method has achieved significant improvements.

A New Convolutional Neural Network-Based Data-Driven Fault Diagnosis Method

Intelligent fault diagnosis is a promising tool to deal with mechanical big data due to its ability in rapidly and efficiently processing collected signals and providing accurate diagnosis results. In traditional intelligent diagnosis methods, however, the features are manually extracted depending on prior knowledge and diagnostic expertise. Such processes take advantage of human ingenuity but are time-consuming and labor-intensive. Inspired by the idea of unsupervised feature learning that uses artificial intelligence techniques to learn features from raw data, a two-stage learning method is proposed for intelligent diagnosis of machines. In the first learning stage of the method, sparse filtering, an unsupervised two-layer neural network, is used to directly learn features from mechanical vibration signals. In the second stage, softmax regression is employed to classify the health conditions based on the learned features. The proposed method is validated by a motor bearing dataset and a locomotive bearing dataset, respectively. The results show that the proposed method obtains fairly high diagnosis accuracies and is superior to the existing methods for the motor bearing dataset. Because of learning features adaptively, the proposed method reduces the need of human labor and makes intelligent fault diagnosis handle big data more easily.

An Intelligent Fault Diagnosis Method Using Unsupervised Feature Learning Towards Mechanical Big Data

Regular inspection of nuclear power plant components is important to guarantee safe operations. However, current practice is time consuming, tedious, and subjective, which involves human technicians reviewing the inspection videos and identifying cracks on reactors. A few vision-based crack detection approaches have been developed for metallic surfaces, and they typically perform poorly when used for analyzing nuclear inspection videos. Detecting these cracks is a challenging task since they are tiny, and noisy patterns exist on the components’ surfaces. This study proposes a deep learning framework, based on a convolutional neural network (CNN) and a Naive Bayes data fusion scheme, called NB-CNN, to analyze individual video frames for crack detection while a novel data fusion scheme is proposed to aggregate the information extracted from each video frame to enhance the overall performance and robustness of the system. To this end, a CNN is proposed to detect crack patches in each video frame, while the proposed data fusion scheme maintains the spatiotemporal coherence of cracks in videos, and the Naive Bayes decision making discards false positives effectively. The proposed framework achieves a 98.3% hit rate against 0.1 false positives per frame that is significantly higher than state-of-the-art approaches as presented in this paper.

NB-CNN: Deep Learning-Based Crack Detection Using Convolutional Neural Network and Naïve Bayes Data Fusion

Recently, to ensure the reliability and safety of modern large-scale industrial processes, data-driven methods have been receiving considerably increasing attention, particularly for the purpose of process monitoring. However, great challenges are also met under different real operating conditions by using the basic data-driven methods. In this paper, widely applied data-driven methodologies suggested in the literature for process monitoring and fault diagnosis are surveyed from the application point of view. The major task of this paper is to sketch a basic data-driven design framework with necessary modifications under various industrial operating conditions, aiming to offer a reference for industrial process monitoring on large-scale industrial processes.

A Review on Basic Data-Driven Approaches for Industrial Process Monitoring

In this paper, two online schemes for an integrated design of fault-tolerant control (FTC) systems with application to Tennessee Eastman (TE) benchmark are proposed. Based on the data-driven design of the proposed fault-tolerant architecture whose core is an observer/residual generator based realization of the Youla parameterization of all stabilization controllers, FTC is achieved by an adaptive residual generator for the online identification of the fault diagnosis relevant vectors, and an iterative optimization method for system performance enhancement. The performance and effectiveness of the proposed schemes are demonstrated through the TE benchmark model.

Real-Time Implementation of Fault-Tolerant Control Systems With Performance Optimization

Performance-based fault detection and fault-tolerant control for automatic control systems

Prediction of remaining useful life based on bidirectional gated recurrent unit with temporal self-attention mechanism

The issue of quality-related fault detection is a hot research topic in the process monitoring community in the recent five years. Several modifications based on partial least squares (PLS) have been proposed to solve the relevant problems for linear systems. For the systems with nonlinear characteristics, some modified algorithms based on kernel partial least squares (KPLS) have also been designed very recently. However, most of the existing methods suffer from the defect that their performances are not stable when the fault intensity increases. More importantly, there is no way yet to solve the linear and nonlinear problems in a uniform algorithm structure, which is very important for simplifying the design steps of fault detection systems. This paper aims to propose such approaches based on principal component regression (PCR) and kernel principal component regression (KPCR). Such that, relevant problems in linear and nonlinear systems can be solved in the same way. Two literature examples are used to test the performance of the proposed approaches.

Hao Luo

Papers

A Review on Basic Data-Driven Approaches for Industrial Process Monitoring

Real-Time Implementation of Fault-Tolerant Control Systems With Performance Optimization

Performance-based fault detection and fault-tolerant control for automatic control systems

Prediction of remaining useful life based on bidirectional gated recurrent unit with temporal self-attention mechanism

Quality-related fault detection using linear and nonlinear principal component regression