Fault-Diagnosis Applications: Model-Based Condition Monitoring: Actuators, Drives, Machinery, Plants, Sensors, and Fault-tolerant Systems

372 Pages·2011·6.93 MB·English

by  Rolf Isermann (auth.)

Fault-Diagnosis Applications

Rolf Isermann
Fault-Diagnosis Applications
Model-Based Condition Monitoring:
Actuators, Drives, Machinery, Plants,
Sensors, and Fault-tolerant Systems
Prof. Dr. -Ing. Dr. h.c. Rolf Isermann
Technische Universität Darmstadt
Institut für Automatisierungstechnik
Landgraf-Georg-Straße 4
64283 Darmstadt
Germany
[email protected]

ISBN 978-3-642-12766-3 e-ISBN 978-3-642-12767-0
DOI 10.1007/978-3-642-12767-0
Springer Heidelberg Dordrecht London New York

Library of Congress Control Number: 2011926417

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Preface
Withincreasingdemandsforefficiencyandproductqualityandprogressingintegra-
tionofautomaticcontrolsystemsinhigh-costandsafety-criticalprocesses,thefield
ofsupervision(ormonitoring),faultdetectionandfaultdiagnosisplaysanimportant
role. The classical method of supervision is to check the limits of single variables
and alarming of operators. However, this can be improved significantly by taking
intoaccounttheinformationhiddeninallmeasurementsandbyautomaticactionsto
keepthesystemsinoperation.
During the last few decades theoretical and experimental research has shown
newwaystodetectanddiagnosefaults.Onedistinguishesfaultdetectiontorecog-
nizethatafaulthappened, andfaultdiagnosis tofindthecauseandlocationofthe
fault. Advanced methods of fault detection are based on mathematical signal and
processmodelsandonmethodsofsystemtheoryandprocessmodelingtogenerate
faultsymptoms.Fault-diagnosismethodsusecausalfault–symptomrelationshipsby
applying methods from statistical decision, artificial intelligence and soft comput-
ing. Therefore, efficient supervision, fault detection and diagnosis is a challenging
fieldencompassingphysical-orientedsystemtheory,experimentsandcomputations.
Theconsideredsubjectsarealsoknownasconditionmonitoring,faultdetectionand
isolation(FDI)orfaultdetectionanddiagnosis(FDD).
Afurtherimportantfieldisfaultmanagementorassetmanagement.Thismeans
toavoidshutdownsbyearlyfaultdetectionandactionslikeprocesscondition-based
maintenanceorrepair.Ifsuddenfaults,failuresormalfunctionscannotbeavoided,
fault-tolerant systems are required. Through methods of fault detection and recon-
figuration of redundant components, breakdown, and in the case of safety-critical
processes,accidents,maybeavoided.
As the successor to the book Fault-Diagnosis Systems – An Introduction from
FaultDetectiontoFaultTolerancethisbookdescribesapplicationsoffaultdetection
anddiagnosistodifferentkindsoftechnicalprocessesandproducts.
The development of fault-detection and fault-diagnosis methods was paralleled
by experimental investigations with several technical processes at the Institute of
AutomaticControloftheDarmstadtUniversityofTechnologyfromabout1975and
frequently in cooperation with industrial partners. In this way the theoretically de-
VI Preface
velopedmethodscouldbetestedonrealprocessesandtheexperimentalresultsgave
hints for improvements and further ideas. Therefore, this book contains the main
resultsof20differentprocesses,rangingfromelectricaldrivesanddifferentactua-
tors, through machine tools, pumps and pipelines, to heat exchangers. (Theoretical
and practical results for combustion engines are published in another book Engine
ControlandDiagnosis.)
Thebookisanintroductiontotheapplicationoffaultdiagnosisandfaulttoler-
anceintheareasofelectricalengineering,mechanicalandchemicalengineeringand
computer science. It is addressed to students and practicing engineers in research
anddevelopment,designandmanufacturing.Preconditionsarebasicundergraduate
coursesinsystemtheory, automaticcontrol, andmechanical and/or electrical engi-
neering.
The author is grateful to his research associates, who have performed many
theoretical and practical research projects on the subject of this book since 1975,
among them H. Siebert, L. Billmann, G. Geiger, W. Goedecke, S. Nold, U. Raab,
B.Freyermuth,St.Leonhardt,R.Deibert,T.Ho¨fling,T.Pfeufer,M.Ayoubi,P.Balle´,
D.Fu¨ssel,O.Moseler,A.Wolfram,M.Mu¨nchhof,F.HausandM.Beck.
Finally,IespeciallywouldliketothankBrigitteHoppeforthelaboriousandpre-
cisetextsetting,includingthefiguresandtablesincamera-readyformandSpringer-
Verlagfortheexcellentcooperation.
Darmstadt,September,2010
RolfIsermann
Contents
ListofSymbols .................................................... XIII
1 Introduction................................................... 1
1.1 Processautomationandprocesssupervision/conditionmonitoring.. 1
1.2 Productlifecyclesandfaultmanagement(assetmanagement) ..... 3
1.3 Contents .................................................. 5
PartI Supervision,FaultDetectionandDiagnosis
2 Supervision, fault-detection and diagnosis methods – a short
introduction .................................................. 11
2.1 Basictasksofsupervision ................................... 11
2.2 Terminology............................................... 17
2.2.1 Faults,failures,malfunctions .......................... 17
2.2.2 Reliability,availability,safety.......................... 19
2.2.3 Faulttoleranceandredundancy ........................ 21
2.3 Knowledge-basedfaultdetectionanddiagnosis ................. 22
2.3.1 Analyticsymptomgeneration.......................... 22
2.3.2 Heuristicsymptomgeneration ......................... 23
2.3.3 Faultdiagnosis ...................................... 24
2.4 Signal-basedfault-detectionmethods .......................... 24
2.4.1 Limitcheckingofabsolutevalues ...................... 25
2.4.2 Trendchecking...................................... 25
2.4.3 Changedetectionwithbinarythresholds................. 26
2.4.4 Adaptivethresholds .................................. 27
2.4.5 Plausibilitychecks ................................... 28
2.4.6 Signal-analysismethods .............................. 29
2.5 Process-model-basedfault-detectionmethods ................... 30
2.5.1 Processmodelsandfaultmodeling ..................... 32
2.5.2 Faultdetectionwithparameterestimation................ 34
VIII Contents
2.5.3 Faultdetectionwithstateobserversandstateestimation.... 35
2.5.4 Faultdetectionwithparityequations .................... 37
2.5.5 Directreconstructionofnon-measurablevariables......... 38
2.6 Fault-diagnosismethods..................................... 39
2.6.1 Classificationmethods................................ 39
2.6.2 Inferencemethods ................................... 41
2.7 Faultdetectionanddiagnosisinclosedloop .................... 41
2.8 Dataflowstructureforsupervision(conditionmonitoring) ........ 43
PartII DrivesandActuators
3 Faultdiagnosisofelectricaldrives................................ 49
3.1 Direct-currentmotor(DC) ................................... 49
3.1.1 StructureandmodelsofaDCmotor .................... 49
3.1.2 Faultdetectionwithparityequations .................... 52
3.1.3 Faultdetectionwithparameterestimation................ 54
3.1.4 Experimentalresultsforfaultdetection(SELECT) ........ 55
3.1.5 Experimentalresultsforfaultdiagnosiswithalearning
fault-symptomtree................................... 57
3.1.6 Conclusions......................................... 63
3.2 Alternating-currentmotor(AC)............................... 63
3.2.1 Structureandmodelsofinductionmotors(asynchronous
motors) ............................................ 64
3.2.2 Signal-basedfaultdetectionofthepowerelectronics....... 66
3.2.3 Model-basedfaultdetectionoftheACmotor ............. 71
3.2.4 Conclusions......................................... 80
4 Faultdiagnosisofelectricalactuators............................. 81
4.1 Electromagneticactuator .................................... 81
4.1.1 Positioncontrol...................................... 83
4.1.2 Faultdetectionwithparameterestimation................ 85
4.2 Electricalautomotivethrottlevalveactuator .................... 87
4.2.1 Structureandmodelsoftheactuator .................... 88
4.2.2 Inputtestcycleforqualitycontrol ...................... 89
4.2.3 Faultdetectionwithparameterestimation................ 91
4.2.4 Faultdetectionwithparityequation..................... 94
4.2.5 Faultdiagnosis ...................................... 95
4.2.6 Fault-diagnosisequipment............................. 96
4.2.7 Conclusions......................................... 98
4.3 BrushlessDCmotorandaircraftcabinpressurevalve ............ 98
4.3.1 Structureandmodels ................................. 98
4.3.2 Faultdetectionwithparameterestimation................ 101
4.3.3 Faultdetectionwithparityequations .................... 102
4.3.4 Conclusions......................................... 104
Contents IX
5 Faultdiagnosisoffluidicactuators ............................... 105
5.1 Hydraulicservoaxis ........................................ 105
5.1.1 Hydraulicservoaxisstructure.......................... 106
5.1.2 Faultsofhydraulicservoaxes.......................... 106
5.1.3 Modelsofspoolvalveandcylinder ..................... 111
5.1.4 Faultdetectionanddiagnosisofvalveandcylinder ........ 115
5.1.5 Conclusions......................................... 121
5.2 Pneumaticactuators ........................................ 121
5.2.1 Pneumatic-actuatorconstruction........................ 122
5.2.2 Faultsofpneumaticvalves ............................ 124
5.2.3 Modelsofpneumaticvalves ........................... 125
5.2.4 Faultdetectionwithvalvecharacteristics ................ 128
5.2.5 Faultdetectionofflowvalveswithpneumaticposition
controller........................................... 130
5.2.6 Faultdetectionofflow valves withelectronicposition
controller........................................... 138
5.2.7 Conclusions......................................... 139
PartIII MachinesandPlants
6 Faultdiagnosisofpumps........................................ 143
6.1 Centrifugalpumps.......................................... 143
6.1.1 Stateoftheartinpumpsupervisionandfaultdetection..... 143
6.1.2 Modelsofcentrifugalpumpsandpipesystems............ 146
6.1.3 Faultdetectionwithparameterestimation................ 149
6.1.4 Fault detection with nonlinear parity equations and
parameterestimation ................................. 156
6.1.5 Faultdetectionwithvibrationsensors ................... 165
6.1.6 Conclusions......................................... 169
6.2 Reciprocatingpumps ....................................... 170
6.2.1 Structureofadiaphragmpump......................... 171
6.2.2 Modelsofadiaphragmpump .......................... 172
6.2.3 Faultdetectionandfaultdiagnosisofthehydraulicpump... 172
6.2.4 Faultdetectionofthepumpdrive....................... 177
6.2.5 Conclusions......................................... 178
7 Leakdetectionofpipelines ...................................... 181
7.1 Stateoftheartinpipelinesupervision ......................... 181
7.2 Modelsofpipelines......................................... 182
7.3 Model-basedleakdetection .................................. 187
7.3.1 Leakdetectionwithstateobservers ..................... 188
7.3.2 Leakdetectionwithmassbalanceandcorrelationanalysis
forliquidpipelines ................................... 190
7.3.3 Leakdetectionforgaspipelines ........................ 195