Abstract

In the process of Unmanned Aerial Vehicle (UAV) flight testing, plenty of compound faults exist, which could be composed of concurrent single faults or over-limit states alarmed by Built-In-Test (BIT) equipment. At present, there still lacks a suitable automatic labeling approach for UAV flight data, effectively utilizing the information of the BIT record. The performance of the originally employed flight data-driven fault diagnosis models based on machine learning needs to be improved as well. A compound fault labeling and diagnosis method based on actual flight data and the BIT record of the UAV during flight test phase is proposed, through labeling the flight data with compound fault modes corresponding to concurrent single faults recorded by the BIT system, and upgrading the original diagnosis model based on Gradient Boosting Decision Tree (GBDT) and Fully Convolutional Network (FCNN), to eXtreme Gradient Boosting (XGBoost), Light Gradient Boosting Machine (LightGBM) and modified Convolutional Neural Network (CNN). The experimental results based on actual test flight data show that the proposed method could effectively label the flight data and obtain a significant improvement in diagnostic performance, appearing to be practical in the UAV test flight process.

Highlights

  • The Unmanned Aerial Vehicle (UAV), as a typical complex electromechanical system, has been used in military and commercial fields widely, but is accompanied with a high fault rate

  • With reference to the ground maintenance experience and FMECA, we analyzed all the 98 classes of states to set 49 new compound fault classes including 284,393 cases, through merging some classes corresponding to the same fault mode and deleting a few abnormal instances caused by transmission and storage, etc

  • In the process of UAV flight testing, plenty of compound faults exist, which could be composed of concurrent single faults or over-limit states alarmed by a BIT system

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Summary

Introduction

The Unmanned Aerial Vehicle (UAV), as a typical complex electromechanical system, has been used in military and commercial fields widely, but is accompanied with a high fault rate. With the continuous development of Prognostics Health Management (PHM) technology, a great quantity of sensors are employed in the new generation of large fixed-wing UAV, bringing the explosive growth of flight data scale [5]. The data-driven methods, thanks to the growth of the data scale, are gradually replacing the traditional Physics of Failure (PoF) methods [6], becoming the mainstream for fault diagnosis. Most of the common faults of current UAVs could be detected and alarmed in real time by the advanced Built-In-Test (BIT) system [7], but single faults or over-limit states of one component are reflected poorly. In actual test flight activity of UAVs, there are multiple

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