Fault Detection And Diagnosis Research Articles

Particle-Filter-Based Fault Diagnosis for the Startup Process of an Open-Cycle Liquid-Propellant Rocket Engine.

This study introduces a fault diagnosis algorithm based on particle filtering for open-cycle liquid-propellant rocket engines (LPREs). The algorithm serves as a model-based method for the startup process, accounting for more than 30% of engine failures. Similar to the previous fault detection and diagnosis (FDD) algorithm for the startup process, the algorithm in this study is composed of a nonlinear filter to generate residuals, a residual analysis, and a multiple-model (MM) approach to detect and diagnose faults from the residuals. In contrast to the previous study, this study makes use of the modified cumulative sum (CUSUM) algorithm, widely used in change-detection monitoring, and a particle filter (PF), which is theoretically the most accurate nonlinear filter. The algorithm is confirmed numerically using the CUSUM and MM methods. Subsequently, the FDD algorithm is compared with an algorithm from a previous study using a Monte Carlo simulation. Through a comparative analysis of algorithmic performance, this study demonstrates that the current PF-based FDD algorithm outperforms the algorithm based on other nonlinear filters.

Optimized data driven fault detection and diagnosis in chemical processes

Fault detection and diagnosis (FDD) is crucial for ensuring process safety and product quality in the chemical industry. Despite the large amounts of process data recorded and stored in chemical plants, most of them are not well-labeled, and their conditions are not adequately specified. In this study, an optimized data-driven FDD model was developed for a chemical process based on automatic clustering algorithms. Due to data preprocessing importance, feature selection was performed by a non-dominated sorting genetic algorithm (NSGAII) based on k-means clustering. The optimal subset of features is selected by comparing clustering results for each subset. The performance of the proposed feature selection method was compared with the Fisher discriminant ratio (FDR), and XGBoost methods. The t-distributed stochastic neighbor embedding (t-SNE), Isomap, and KPCA dimension reduction methods were also employed for feature extraction. Finally, automatic clustering was performed based on metaheuristic algorithms for fault detection and diagnosis. Results were compared with non-automatic clustering methods. The performance of the proposed method was evaluated by examining the Tennessee Eastman and four water tank processes as case studies. The results showed that the proposed method is reliable and capable of online and offline chemical process fault detection and diagnosis. As a result, the findings of this study can be used to stabilize the operation of chemical processes.

A Review of Statistical-Based Fault Detection and Diagnosis with Probabilistic Models

As industrial processes grow increasingly complex, fault identification becomes challenging, and even minor errors can significantly impact both productivity and system safety. Fault detection and diagnosis (FDD) has emerged as a crucial strategy for maintaining system reliability and safety through condition monitoring and abnormality recovery to manage this challenge. Statistical-based FDD methods that rely on large-scale process data and their features have been developed for detecting faults. This paper overviews recent investigations and developments in statistical-based FDD methods, focusing on probabilistic models. The theoretical background of these models is presented, including Bayesian learning and maximum likelihood. We then discuss various techniques and methodologies, e.g., probabilistic principal component analysis (PPCA), probabilistic partial least squares (PPLS), probabilistic independent component analysis (PICA), probabilistic canonical correlation analysis (PCCA), and probabilistic Fisher discriminant analysis (PFDA). Several test statistics are analyzed to evaluate the discussed methods. In industrial processes, these methods require complex matrix operation and cost computational load. Finally, we discuss the current challenges and future trends in FDD.

Adaptive Intelligent Minimum Parameter Singularity Free Sliding Mode Controller Design for Quadrotor

This paper presents a singularity free fast terminal sliding mode control (SFFTSMC) for position and attitude tracking of a quadrotor with unknown dynamics. The contribution of this work is threefold, namely: devising an SFFTSMC strategy using an auxiliary function to eliminate the singularity in the control law, a cost-saving minimum parameter update scheme using a fully connected recurrent neural network (FCRNN) to handle the unknown dynamics of quadrotor and development of an adaptive control law to compensate for the loss of effectiveness of the actuator and saturation effects, considered explicitly, without the requirement of any fault detection and diagnosis (FDD) unit. The proposed approach offers a direct singularity free control action in the presence of unknown dynamics, actuator faults, and saturation. Overall closed-loop stability is guaranteed in finite-time using Lyapunov stability theory and update laws for minimum parameters of FCRNN and fault compensator are derived using the same. Extensive simulations are presented for the trajectory tracking tasks using the proposed method and compared with the existing piece-wise fast terminal sliding mode controller (PFTSMC) and Radial basis function network (RBFN) based fault compensation approach. The proposed method is also validated in the Gazebo simulator via Pixhawk autopilot to demonstrate the feasibility in real-time. <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">Note to Practitioners</i> —This research is motivated by a cost-effective control scheme for quadrotors in cases of unknown/uncertain dynamics, external disturbances, actuator faults, and saturation. Precise quadrotor dynamics are difficult to obtain in real time. Also, there may be parametric uncertainties in quadrotor parameters like mass, inertia, and aerodynamic coefficients. External disturbances like wind gusts are always present in outdoor environments, and it may be the case that quadrotor motors lose their effectiveness due to defective motors or propeller damage while flying. To address these issues, first, it requires a precise control scheme to control the quadrotor while guaranteeing stability to ensure the safety of the quadrotor itself and people in the surrounding environment. Second, the approach should not be computationally heavy, which may sluggish the overall response of the quadrotor. Thus, we propose a control scheme to address these two issues simultaneously using a new fast terminal sliding mode control scheme augmented with FCRNN by updating minimum parameters instead of all the weight parameters of FCRNN. A compensator is introduced to mitigate the effect of unexpected actuator fault and saturation. The proposed approach can be helpful in various quadrotor applications, like pesticide spraying in agriculture, payload transportation, search and rescue, construction, etc., where unknown quadrotor dynamics and unknown payload situations occur.

Fault detection and diagnosis of electric bus air conditioning systems incorporating domain knowledge and probabilistic artificial intelligence

The air conditioning systems in electric city buses usually operate in rapidly changing ambient conditions and are more likely to suffer from mechanical faults. Although many fault detection and diagnosis (FDD) methods have been developed for building air conditioning systems, they are difficult to be applied to bus air conditioners since its operation is highly dynamic and fault-free data are usually unavailable. Therefore, this paper proposes an FDD method for electric bus air conditioners to tackle the above issues. First, the method identifies faults in an unsupervised manner by comparing selected features among a group of peer systems. Then, considering the features are influenced by the operating conditions, Gaussian process regression (GPR) models are established to find the relationships between each feature and its influential parameters. The probabilistic nature of the GPR is used to differentiate predictions with large uncertainty, which are then excluded from FDD. In this way, robustness of the method is evidently improved. Finally, fault indexes are defined to detect and diagnose mechanical faults. We applied the method to a group of air conditioners in a city bus fleet. Results showed that it can effectively identify refrigerant undercharge and indoor and outdoor fan problems with low false positive/genitive rates. Also, the method is highly robust and not sensitive to the faulty systems in the bus fleet.

Explainable finite mixture of mixtures of bounded asymmetric generalized Gaussian and Uniform distributions learning for energy demand management

We introduce a mixture of mixtures of bounded asymmetric generalized Gaussian and uniform distributions. Based on this framework, we propose model-based classification and model-based clustering algorithms. We develop an objective function for the minimum message length (MML) model selection criterion to discover the optimal number of clusters for the unsupervised approach of our proposed model. Given the crucial attention received by Explainable AI (XAI) in recent years, we introduce a method to interpret the predictions obtained from the proposed model in both learning settings by defining their boundaries in terms of the crucial features. Integrating Explainability within our proposed algorithm increases the credibility of the algorithm’s predictions since it would be explainable to the user’s perspective through simple If-Then statements using a small binary decision tree. In this paper, the proposed algorithm proves its reliability and superiority to several state-of-the-art machine learning algorithms within the following real-world applications: fault detection and diagnosis (FDD) in chillers, occupancy estimation and categorization of residential energy consumers.

Domain generalization of chemical process fault diagnosis by maximizing domain feature distribution alignment

Fault detection and diagnosis (FDD) is crucial for ensuring safety and quality control in chemical industry. But data-driven FDD methods are usually trained with samples under certain operating conditions or data domains. This leads to their performance degradation caused by domain shifts in practice. To address this, a new FDD network, termed the DFDA model, has been designed to achieve domain generalization. Distribution of features extracted from fault samples is progressively aligned by supervised contrastive learning, learning vector quantization and gradient reversal adversarial learning in the DFDA model. So that FDD using such aligned features can potentially offer enhanced domain generalization capabilities. The performance of the DFDA model is benchmarked against other state-of-the-art FDD frameworks using data from various domains/modes of the Tennessee Eastman Process and an actual industrial process. The experimental outcomes indicate that the DFDA model consistently outperforms others in five distinct tasks, achieving an average Fault Detection Rate (FDR) that is 23% higher than that of ViT and 16% higher than CausalViT.

Real-Time Simulation and Experimental Implementation of Luenberger Observer-Based Speed Sensor Fault Detection of BLDC Motors

Abstract Modern control systems’ dependability, safety and efficiency have all been improved by studying fault-tolerant control systems (FTCS). FTCS techniques can typically be active or passive controls. The fault detection and diagnosis (FDD) method is used in this study’s active control branch to identify probable faults that could develop in the speed Hall sensors of brushless DC motors (BLDC). FDD methodologies can be categorised into two types, depending on the available data and the process involved: model-based methods and data-based methods. The proposed approach in this study explores the implementation of the Luenberger observer methodology as part of the model-based approach. The chosen methodology was practically implemented and subjected to experimental evaluation. The proposed observer relies on the residual signal, which displays the difference between the plant’s observed and estimated speed signals and serves as a failure alert for the entire system. Given the increasing demand for BLDC motors in various industrial control applications, including medical fields, automation and robotics, this particular motor was selected as a benchmark to thoroughly evaluate and validate the proposed method. The primary contribution of this paper lies in the real-time application of model-based sensor fault detection methods to BLDC motors. The efficiency of the suggested method is showcased through extensive MATLAB simulations, where the obtained results confirm the successful detection of faults with a high level of responsiveness. As a result, the project was successfully implemented in real-time, and the experimental results exhibited a close correlation with the simulated outcomes. This consistency between simulation and practical implementation validates the accuracy and reliability of the proposed methodology for detecting faults in the BLDC motor speed sensor. The results underscore the heightened reliability and safety attained by promptly and accurately detecting sensor faults during the operation of the motor.

Enhancement in the safety and reliability of Pressurized Water reactors using Machine Learning approach

The increasing interest in artificial intelligence and automation within the nuclear industry stems from the hope of elevating the safety and reliability of nuclear power plants by minimizing the impact of human errors. This paper explores the capabilities of machine-learning based fault detection and diagnosis (FDD) models in accurately classifying transient events in a nuclear power plant using the Classification Learners Application from MATLAB. The scope of the research is narrowed to the identification of transient events of the same nature occurring at various locations within the plant. To accomplish this, the Generic Pressurized Water Reactor (GPWR) from the Western Services Cooperation (WSC) was used to simulate 14 transients in the primary system and 10 transients in the secondary system, resulting in two distinct datasets of 108,000 and 79,200 observations. Nine types of classifiers, including Decision Trees, Discriminant Analysis, Support Vector Machines, Logistic Regression, Nearest Neighbors, Naive Bayes, Kernel Approximation, Ensembles, and Neural Networks, with a total of 33 predefined models, were trained and validated. The K-Nearest Neighbors model achieved the highest accuracy of 97% in the primary system, while the Efficient Linear Discriminant and Logistic Regression models achieved the highest average accuracy of 99% in the secondary system. The assessment of the top-performing models was conducted through a comprehensive analysis employing key classification model evaluation metrics, such as the confusion matrix, accuracy, precision, recall, and the F1 score. In an effort to optimize the models, the study integrated feature selection using the minimum Redundancy Maximum Relevance (mRMR) algorithm. Additionally, the investigation explored different validation schemes, including both holdout and k-fold cross-validation schemes, resulting in a substantial reduction in training time without significantly compromising the overall accuracy of the models. The optimized models in this study demonstrated remarkable prediction accuracies, consistently exceeding 94%. Despite the complexity of the models and the intricacies involved in the training process, the training times ranged from 10 to 1800 s, reflecting the efficiency and robustness of the implemented optimization techniques. The results of this study underscore the potential of machine learning models in identifying transient events in nuclear reactors, showcasing their promising capabilities while maintaining low computational and execution costs. This suggests their efficacy in optimizing safe and efficient operational practices within nuclear facilities.

A modified transformer and adapter-based transfer learning for fault detection and diagnosis in HVAC systems

Fault detection and diagnosis (FDD) of heating, ventilation, and air conditioning (HVAC) systems can help to improve the energy saving in building energy systems. However, most data-driven trained FDD models have limited generalizability and can only be applied to specific systems. The diversity of HVAC systems and the high cost of data acquisition present challenges for the practical application of FDD. Transfer learning technology can be employed to mitigate this problem by training a model on systems with sufficient data and then transfer it to other systems with limited data. In this study, a novel transfer learning approach for HVAC FDD is proposed. First, the transformer model is modified to incorporate one encoder and two decoders connected, enabling two outputs. This modified transformer model accommodates absent features in the target domain and serves as a robust foundation for transfer learning. It has effective performance in complex systems and achieves an accuracy of 91.38% for a system with 16 faults and multiple fault severity levels. Second, the adapter-based parameter-efficient transfer learning method, facilitating the transfer of trained models simply by inserting small adapter modules, is investigated as the transfer learning strategy. Results demonstrate that this adapter-based transfer learning approach achieves satisfactory performance similar to full fine-tuning with fewer trainable parameters. It works well with limited data amount in target domain. Furthermore, the findings highlight the significance of adapters positioned near the bottom and top layers, emphasizing their critical role in facilitating successful transfer learning.

Advancements in condition monitoring and fault diagnosis of rotating machinery: A comprehensive review of image-based intelligent techniques for induction motors

Recently, condition monitoring (CM) and fault detection and diagnosis (FDD) techniques for rotating machinery (RM) have witnessed substantial advancements in recent decades, driven by the increasing demand for enhanced reliability, efficiency, and safety in industrial operations. CM of valuable and high-cost machinery is crucial for performance tracking, reducing maintenance costs, enhancing efficiency and reliability, and minimizing mechanical failures. While various FDD methods for RM have been developed, these predominantly focus on signal processing diagnostics techniques encompassing time, frequency, and time-frequency domains, intelligent diagnostics, image processing, data fusion, data mining, and expert systems. However, there is a noticeable knowledge gap regarding the specific review of image-based CM and FDD. The objective of this research is to address the aforementioned gap in the literature by conducting a comprehensive review of image-based intelligent techniques for CM and fault FDD specifically applied to induction motors (IMs). The focus of the study is to explore the utilization of image-based methods in the context of IMs, providing a thorough examination of the existing literature, methodologies, and applications. Furthermore, the integration of image-based techniques in CM and FDD holds promise for enhanced accuracy, as visual information can provide valuable insights into the physical condition and structural integrity of the IMs, thereby facilitating early FDD and proactive maintenance strategies. The review encompasses the three main faults associated with IMs, namely bearing faults, stator faults, and rotor faults. Furthermore, a thorough assessment is conducted to analyze the benefits and drawbacks associated with each approach, thereby enabling an evaluation of the efficacy of image-based intelligent techniques in the context of CM and FDD. Finally, the paper concludes by highlighting key issues and suggesting potential avenues for future research.

A novel exergy-related fault detection and diagnosis framework with transformer-based conditional generative adversarial networks for hot strip mill process

Fault detection and diagnosis (FDD) plays a crucial role in the iron and steel industry. However, the iron and steel industry have unique complex characteristics such as high energy consumption, temporal and spatial correlation, and data imbalance, which makes the application of traditional FDD methods ineffective. With the development of FDD, deep learning-based methods have attracted more and more attention. To address the above issues, this work combines the advantages of transformer and conditional generative adversarial networks (CGAN) to propose a novel exergy-related FDD framework with transformer-based CGAN (TransCGAN). Firstly, we extract exergy-related variables and convert one-dimensional data into image data to preserve spatiotemporal information. Next, the transformer encoder is used as the basic block of CGAN to capture the relationship between normal and fault data, and generate fault samples. Then, the generated data and original data are mixed to train the proposed FDD model. Finally, the feasibility of TransCGAN is verified by the hot strip mill process (HSMP). Compared with other state-of-the-art (SOTA) methods, the proposed method has higher fault detection rate and better fault diagnostic performance.

Fault detection, diagnosis and calibration of heating, ventilation and air conditioning sensors by combining principal component analysis and improved bayesian inference

Sensors are crucial components in heating, ventilation and air conditioning (HVAC) systems. When sensors fault, the HVAC system deviates from normal operation, resulting in an increase in energy consumption and a decline in equipment lifespan. Therefore, it is vital to detect, diagnose and calibrate the sensor faults. Bayesian Inference (BI) in data-driven methods is highly effective for sensor calibration. However, its application faces two major shortcomings. First, the conventional BI method cannot effectively calibrate sensor drift faults. Second, the BI method relies on sensor fault detection and diagnosis (FDD). To address these shortcomings, this study proposed an improved BI (imBI) method that enhanced the capability of BI to calibrate drift faults by updating the calibration constant x. Moreover, sensor fault detection, diagnosis and calibration (FDDC) were conducted by combining Principal Component Analysis (PCA) with the imBI method (PCA-imBI). The proposed methods were validated through two case studies involving a chiller system and an air handling unit (AHU) system, having different degrees of bias faults and drift faults in temperature sensors, differential pressure sensors and flow sensors. The results demonstrated that the PCA-imBI method effectively achieved FDDC for both bias and drift faults. Considering the case studies, the average calibration rates for bias and drift faults reached 99.74 % and 95.29 %, respectively. For drift fault calibration, the imBI method outperformed the dynamic calibration method and PCA reconstruction method by 16.04 % and 4.31 %, respectively.

Deep recurrent neural networks based Bayesian optimization for fault diagnosis of uncertain GCPV systems depending on outdoor condition variation

Energy generated from renewable sources is exposed to extremely dynamic variations in climatic conditions as well as uncertainties (current/voltage variability, noise, measurement errors.). These conditions are relevant issues to be considered when monitoring renewable energy conversion (REC) systems. In fact, these uncertain systems are subjected to many failures leading to performance degradation and long downtime maintenance periods. Therefore, fault detection and diagnosis (FDD) are essential to ensure its high dependability. This paper proposes an FDD under climatic conditions variability of uncertain REC systems using deep recurrent neural networks (DRNNs) techniques. Firstly, a novel modeling strategy for REC systems is built. Secondly, different DRNN-based interval-valued data methods are intended to differentiate between the various REC systems operating states. Finally, the hyperparameters of the proposed techniques are tuned using the Bayesian optimization algorithm. The efficiency and robustness of the novel strategy are demonstrated through REC application, using grid-connected photovoltaic (GCPV) systems. The obtained results show the efficiency of the developed strategy by reaching an accuracy rate of 92.40%.

Barriers and drivers for implementation of automatic fault detection and diagnosis in buildings and HVAC systems: An outlook from industry experts

This study aimed to assess the current status of Fault Detection and Diagnosis (FDD) implementation in building and Heating, Ventilation and Air Conditioning (HVAC) systems in the building industry. Semi-structured qualitative interviews were conducted with 29 experts from different HVAC company types in the building industry. In addition, a literature review was performed to investigate academic research on FDD implementation. The study identified barriers and drivers to implementing FDD systems, these included; technological and technical, economic and business, users, social and societal, and regulatory. An Automatic Fault Detection and Diagnosis (AFDD) implementation matrix was developed to evaluate FDD implementation in building systems, and all interviewed companies were classified based on their FDD knowledge, services, and type. Results show that expert-rule systems are still prevalent in the industry. The literature review revealed a scarcity of FDD implementation studies in academic research due to challenges in testing and validating results in actual building operation conditions. Lastly, this study discusses the key findings: 1) FDD does not sell, 2) Lack of actively engaging and promoting FDD services, 3) FDD seems to be an academic definition, 4) The bottlenecks: The fault handling process and user’s mindset towards FDD, and 5) Governmental regulations and legislatives drive the implementation focus.

Performance Evaluation of Chiller Fault Detection and Diagnosis Using Only Field-Installed Sensors

Owing to the rapid expansion of data science, data-driven methods have emerged as a dominant trend in chiller fault detection and diagnosis (FDD). Most of these methods prioritize feature selection to achieve optimal diagnostic performance. However, on-site research indicates a common installation of a limited number of sensors, coupled with a necessity to minimize diagnostic costs. This discrepancy between existing research’s feature selection principles and the current on-site sensor installation status presents a significant challenge. To facilitate the practical implementation of data-driven methods in real chiller units, this study addresses a critical question: under the constraint of limited on-site sensor installations, what is the optimal performance achievable by data-driven methods and their improved versions? To answer this, only features derived from commonly installed sensors on field chillers are chosen as indicators for typical chiller faults. The FDD performance of six frequently used data-driven methods, namely, back-propagation neural network, convolutional neural network, support vector machine, support vector data description, Bayesian network, and random forest, along with their improved versions, is comprehensively evaluated and validated using experimental data, considering four evaluation metrics. The conclusions drawn in this paper provide valuable insights for users/manufacturers with limited or no budget, detailing the best achievable diagnostic performance for each typical fault and offering guidance for those aiming to further enhance FDD performance.

Fault detection and diagnosis of energy system based on deep learning image recognition model under the condition of imbalanced samples

Faults in energy systems impact the reliability of the energy supply and cause energy waste. Data-driven fault detection and diagnosis (FDD) methods can detect and diagnose system faults by mining historical operational data. However, the quantitative imbalance between fault and normal samples degrades the performance of the FDD method. Therefore, this study proposes a novel deep learning-based FDD method under the condition of imbalanced samples that converts the time-series signals into an image signal to extract the timing and coupling features, and then applies the improved conditional variational autoencoder-generative adversarial network (CVAE-GAN) to generate fault samples for balancing the training sample set. Subsequently, according to the framework of image recognition, a two-dimensional convolutional neural network was adopted to identify the image samples and achieve FDD. The experimental results showed that, under the condition of imbalanced samples, the proposed method could increase diagnosis accuracy by an average of 5.71% compared with other common data-driven methods. After the samples were augmented with the improved CVAE-GAN, the accuracy improved by an average of 3.79%. Consequently, the feasibility and superiority of the proposed method were demonstrated.

Selection of relevant features to detect and diagnose single and multiple simultaneous soft faults in air-source heat pumps

Soft faults in air-source heat pump systems can cause various issues, such as decreased performance, increased energy consumption, and long-term damage. This paper presents a comprehensive modeling approach of air-source heat pumps that considers individual and simultaneous soft faults validated against empirical experiments from the literature, a perspective limited in previous research. The methodology is based on the simulation of fault-free and faulty system performance utilizing heat pump modeling software. The results are a selection of variables and their trends to select the appropriate features to detect and diagnose single and double soft faults. The model also computes the impacts of these combined faults on COP, revealing significant reductions. Specifically, combinations of overcharge with condenser fouling and undercharge with compressor valve leakages induce COP reductions ranging from 17% to 38%, depending on operating conditions. The model can be used to develop faulty heat pump data, which can be adapted to other system typologies and conditions and used as input for data-driven Fault Detection and Diagnosis (FDD) methodologies.

Sensitivity analysis of an automated fault detection algorithm for residential air-conditioning systems

The state of the art of fault detection and diagnosis (FDD) for residential air-conditioning systems is expensive and not yet amenable to widespread implementation. FDD for homes can significantly reduce utility costs, and increase the lifespan of the equipment. The cost barriers currently, however, make FDD for homes economically unviable for large scale implementation. In prior work, we offered a solution to reduce FDD costs by proposing an automated fault detection algorithm to serve as a screening step before more expensive FDD tests can be conducted. The algorithm uses only the home thermostat and local weather information to identify thermodynamic parameters and detect high-impact air-conditioning faults, including those that occur during equipment installation. We had tested the algorithm on a single EnergyPlusTM model of a home in Orlando, Florida. The thermodynamic parameter identification process is highly nonconvex involving several local optimal solutions. In this paper we propose a novel method to select the best model for fault detection from among the list of local optimal solutions to make the algorithm more robust to homes of different construction, without which the fault detection process would be infeasible. Another unique contribution of the paper is implementing the solution on real-world data. We also bring the algorithm closer to market by testing it on real-world data. We implement the algorithm on data obtained from experiments conducted by the Florida Solar Energy Center (FSEC) on a laboratory home equipped with a heat pump where faults were intentionally added for a period of seven months. The algorithm successfully detected an undercharge fault with 70.6% accuracy, concurrent duct leakage and undercharge faults with 85.2% accuracy, and duct leakage faults with 69.1% accuracy. A sensitivity analysis is also performed on EnergyPlus models of nine types of homes that vary in construction to demonstrate the robustness of the algorithm. The algorithm achieves an average accuracy of 71% for no-fault condition, 77% for 40% undercharge fault, and 76% for duct-leak fault.

A Flexible Probabilistic Framework With Concurrent Analysis of Continuous and Categorical Data for Industrial Fault Detection and Diagnosis

Operational data from industrial processes typically consist of continuous and categorical variables. They reveal different aspects of the operational conditions, and both are useful for comprehensive fault detection and diagnosis (FDD). However, due to the multiple production modes, the variables usually do not follow Gaussian or Bernoulli distributions. Furthermore, their correlations can be different across normal and various faulty classes. Thus, the main challenge lies in how to properly fuse the complementary information in the two types of variables and accurately characterize the complicated distribution for each class. This work proposes a flexible probabilistic framework that can concurrently analyze continuous and categorical variables for FDD. Our framework specifies a finite mixture model for each class. Thus, it can handle non-Gaussian and non-Bernoulli variables and capture their correlations under the conditional independence assumption. We then introduce the variational inference for parameter estimation, which makes our framework adaptive to the different distributions of various classes. Furthermore, a unified statistical index is designed for two types of variables, giving our method extra capability to distinguish unknown faults. Finally, the effectiveness of our method is validated on the Tennessee Eastman (TE) process and a practical industrial plant process. The average <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">F1</i> score of our method is improved by 3.4/3.9 percentage points in the single-mode/multimode situation on the TE process compared with traditional mixture discriminant analysis. In the industrial plant process, when unknown faults are added, the average <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">F1</i> score of our method is 91.1% and only 1.2 percentage points lower than that on the test set without unknown faults.