Remaining Useful Life Prediction Method for Multi-Component System Considering Maintenance:Subsea Christmas Tree System as A Case Study

Maintenance is an important technical measure to maintain and restore the performance status of equipment and ensure the safety of the production process in industrial production,and is an indispensable part of prediction and health management.However,most of the existing remaining useful life(RUL)prediction methods assume that there is no maintenance or only perfect maintenance during the whole life cycle;thus,the predicted RUL value of the system is obviously lower than its actual operating value.The complex environment of the system further increases the difficulty of maintenance,and its maintenance nodes and maintenance degree are limited by the construction period and working conditions,which increases the difficulty of RUL prediction.An RUL prediction method for a multi-omponent system based on the Wiener process considering maintenance is proposed.The performance degradation model of components is established by a dynamic Bayesian network as the initial model,which solves the uncertainty of insufficient data problems.Based on the experience of experts,the degree of degradation is divided according to Poisson process simulation random failure,and different maintenance strategies are used to estimate a variety of condition maintenance factors.An example of a subsea tree system is given to verify the effectiveness of the proposed method.

Accurate and efficient remaining useful life prediction of batteries enabled by physics-informed machine learning

The safe and reliable operation of lithium-ion batteries necessitates the accurate prediction of remaining useful life(RUL).However,this task is challenging due to the diverse ageing mechanisms,various operating conditions,and limited measured signals.Although data-driven methods are perceived as a promising solution,they ignore intrinsic battery physics,leading to compromised accuracy,low efficiency,and low interpretability.In response,this study integrates domain knowledge into deep learning to enhance the RUL prediction performance.We demonstrate accurate RUL prediction using only a single charging curve.First,a generalisable physics-based model is developed to extract ageing-correlated parameters that can describe and explain battery degradation from battery charging data.The parameters inform a deep neural network(DNN)to predict RUL with high accuracy and efficiency.The trained model is validated under 3 types of batteries working under 7 conditions,considering fully charged and partially charged cases.Using data from one cycle only,the proposed method achieves a root mean squared error(RMSE)of 11.42 cycles and a mean absolute relative error(MARE)of 3.19%on average,which are over45%and 44%lower compared to the two state-of-the-art data-driven methods,respectively.Besides its accuracy,the proposed method also outperforms existing methods in terms of efficiency,input burden,and robustness.The inherent relationship between the model parameters and the battery degradation mechanism is further revealed,substantiating the intrinsic superiority of the proposed method.

Remaining Useful Life for Heavy-Duty Railway Cast Steel Knuckles Based on Crack Growth Behavior with Hypothetical Distributions

The current research on the integrity of critical structures of rail vehicles mainly focuses on the design stage,which needs an effective method for assessing the service state.This paper proposes a framework for predicting the remaining useful life(RUL)of in-service structures with and without visible cracks.The hypothetical distribution and delay time models were used to apply the equivalent crack growth life data of heavy-duty railway cast steel knuckles,which revealed the evolution characteristics of the crack length and life scores of the knuckle under different fracture failure modes.The results indicate that the method effectively predicts the RUL of service knuckles in different failure modes based on the cumulative failure probability curves for different locations and surface crack lengths.This study proposes an RUL prediction framework that supports the dynamic overhaul and state maintenance of knuckle fatigue cracks.

A Hybrid Approach for Predicting the Remaining Useful Life of Bearings Based on the RReliefF Algorithm and Extreme Learning Machine

Accurately predicting the remaining useful life(RUL)of bearings in mining rotating equipment is vital for mining enterprises.This research aims to distinguish the features associated with the RUL of bearings and propose a prediction model based on these selected features.This study proposes a hybrid predictive model to assess the RUL of rolling element bearings.The proposed model begins with the pre-processing of bearing vibration signals to reconstruct sixty time-domain features.The hybrid model selects relevant features from the sixty time-domain features of the vibration signal by adopting the RReliefF feature selection algorithm.Subsequently,the extreme learning machine(ELM)approach is applied to develop a predictive model of RUL based on the optimal features.The model is trained by optimizing its parameters via the grid search approach.The training datasets are adjusted to make them most suitable for the regression model using the cross-validation method.The proposed hybrid model is analyzed and validated using the vibration data taken from the public XJTU-SY rolling element-bearing database.The comparison is constructed with other traditional models.The experimental test results demonstrated that the proposed approach can predict the RUL of bearings with a reliable degree of accuracy.

Remaining Useful Life Prediction of Rail Based on Improved Pulse Separable Convolution Enhanced Transformer Encoder

In order to prevent possible casualties and economic loss, it is critical to accurate prediction of the Remaining Useful Life (RUL) in rail prognostics health management. However, the traditional neural networks is difficult to capture the long-term dependency relationship of the time series in the modeling of the long time series of rail damage, due to the coupling relationship of multi-channel data from multiple sensors. Here, in this paper, a novel RUL prediction model with an enhanced pulse separable convolution is used to solve this issue. Firstly, a coding module based on the improved pulse separable convolutional network is established to effectively model the relationship between the data. To enhance the network, an alternate gradient back propagation method is implemented. And an efficient channel attention (ECA) mechanism is developed for better emphasizing the useful pulse characteristics. Secondly, an optimized Transformer encoder was designed to serve as the backbone of the model. It has the ability to efficiently understand relationship between the data itself and each other at each time step of long time series with a full life cycle. More importantly, the Transformer encoder is improved by integrating pulse maximum pooling to retain more pulse timing characteristics. Finally, based on the characteristics of the front layer, the final predicted RUL value was provided and served as the end-to-end solution. The empirical findings validate the efficacy of the suggested approach in forecasting the rail RUL, surpassing various existing data-driven prognostication techniques. Meanwhile, the proposed method also shows good generalization performance on PHM2012 bearing data set.

Prediction Method of Equipment Remaining Life Based on Self-Attention Long Short-Term Memory Neural Network

Aiming at the problem of insufficient consideration of the correlation between components in the prediction of the remaining life of mechanical equipment,the method of remaining life prediction that combines the self-attention mechanism with the long short-term memory neural network(LSTM-NN)is proposed,called Self-Attention-LSTM.First,the auto-encoder is used to obtain the component-level state information;second,the state information of each component is input into the self-attention mechanism to learn the correlation between components;then,the multi-component correlation matrix is added to the LSTM input gate,and the LSTM-NN is used for life prediction.Finally,combined with the commercial modular aero-propulsion system simulation data set(C-MAPSS),the experiment was carried out and compared with the existing methods.Research results show that the proposed method can achieve better prediction accuracy and verify the feasibility of the method.

Remaining Useful Life Prediction With Partial Sensor Malfunctions Using Deep Adversarial Networks

In recent years,intelligent data-driven prognostic methods have been successfully developed,and good machinery health assessment performance has been achieved through explorations of data from multiple sensors.However,existing datafusion prognostic approaches generally rely on the data availability of all sensors,and are vulnerable to potential sensor malfunctions,which are likely to occur in real industries especially for machines in harsh operating environments.In this paper,a deep learning-based remaining useful life(RUL)prediction method is proposed to address the sensor malfunction problem.A global feature extraction scheme is adopted to fully exploit information of different sensors.Adversarial learning is further introduced to extract generalized sensor-invariant features.Through explorations of both global and shared features,promising and robust RUL prediction performance can be achieved by the proposed method in the testing scenarios with sensor malfunctions.The experimental results suggest the proposed approach is well suited for real industrial applications.

A Hybrid Ensemble Deep Learning Approach for Early Prediction of Battery Remaining Useful Life

Accurate estimation of the remaining useful life(RUL)of lithium-ion batteries is critical for their large-scale deployment as energy storage devices in electric vehicles and stationary storage.A fundamental understanding of the factors affecting RUL is crucial for accelerating battery technology development.However,it is very challenging to predict RUL accurately because of complex degradation mechanisms occurring within the batteries,as well as dynamic operating conditions in practical applications.Moreover,due to insignificant capacity degradation in early stages,early prediction of battery life with early cycle data can be more difficult.In this paper,we propose a hybrid deep learning model for early prediction of battery RUL.The proposed method can effectively combine handcrafted features with domain knowledge and latent features learned by deep networks to boost the performance of RUL early prediction.We also design a non-linear correlation-based method to select effective domain knowledge-based features.Moreover,a novel snapshot ensemble learning strategy is proposed to further enhance model generalization ability without increasing any additional training cost.Our experimental results show that the proposed method not only outperforms other approaches in the primary test set having a similar distribution as the training set,but also generalizes well to the secondary test set having a clearly different distribution with the training set.The PyTorch implementation of our proposed approach is available at https://github.com/batteryrul/battery_rul_early_prediction.

Machine learning techniques for prediction of capacitance and remaining useful life of supercapacitors: A comprehensive review

Supercapacitors are appealing energy storage devices for their promising features like high power density,outstanding cycling stability,and a quick charge–discharge cycle.The exceptional life cycle and ultimate power capability of supercapacitors are needed in the transportation and renewable energy generation sectors.Hence,predicting the capacitance and lifecycle of supercapacitors is significant for selecting the suitable material and planning replacement intervals for supercapacitors.In addition,system failures can be better addressed by accurately forecasting the lifecycle of SCs.Recently,the use of machine learning for performance prediction of energy storage materials has drawn increasing attention from researchers globally because of its superiority in prediction accuracy,time efficiency,and costeffectiveness.This article presents a detailed review of the progress and advancement of ML techniques for the prediction of capacitance and remaining useful life(RUL)of supercapacitors.The review starts with an introduction to supercapacitor materials and ML applications in energy storage devices,followed by workflow for ML model building for supercapacitor materials.Then,the summary of machine learning applications for the prediction of capacitance and RUL of different supercapacitor materials including EDLCs(carbon based materials),pesudocapacitive(oxides and composites)and hybrid materials is presented.Finally,the general perspective for future directions is also presented.

End-cloud collaboration method enables accurate state of health and remaining useful life online estimation in lithium-ion batteries

Though the lithium-ion battery is universally applied,the reliability of lithium-ion batteries remains a challenge due to various physicochemical reactions,electrode material degradation,and even thermal runaway.Accurate estimation and prediction of battery health conditions are crucial for battery safety management.In this paper,an end-cloud collaboration method is proposed to approach the track of battery degradation process,integrating end-side empirical model with cloud-side data-driven model.Based on ensemble learning methods,the data-driven model is constructed by three base models to obtain cloud-side highly accurate results.The double exponential decay model is utilized as an empirical model to output highly real-time prediction results.With Kalman filter,the prediction results of end-side empirical model can be periodically updated by highly accurate results of cloud-side data-driven model to obtain highly accurate and real-time results.Subsequently,the whole framework can give an accurate prediction and tracking of battery degradation,with the mean absolute error maintained below 2%.And the execution time on the end side can reach 261μs.The proposed end-cloud collaboration method has the potential to approach highly accurate and highly real-time estimation for battery health conditions during battery full life cycle in architecture of cyber hierarchy and interactional network.

Remaining useful life prediction of aero-engines based on random-coefficient regression model considering random failure threshold

Remaining useful life(RUL)prediction is one of the most crucial components in prognostics and health management(PHM)of aero-engines.This paper proposes an RUL prediction method of aero-engines considering the randomness of failure threshold.Firstly,a random-coefficient regression(RCR)model is used to model the degradation process of aeroengines.Then,the RUL distribution based on fixed failure threshold is derived.The prior parameters of the degradation model are calculated by a two-step maximum likelihood estimation(MLE)method and the random coefficient is updated in real time under the Bayesian framework.The failure threshold in this paper is defined by the actual degradation process of aeroengines.After that,a expectation maximization(EM)algorithm is proposed to estimate the underlying failure threshold of aeroengines.In addition,the conditional probability is used to satisfy the limitation of failure threshold.Then,based on above results,an analytical expression of RUL distribution of aero-engines based on the RCR model considering random failure threshold(RFT)is derived in a closed-form.Finally,a case study of turbofan engine is used to demonstrate the effectiveness and superiority of the RUL prediction method and the parameters estimation method of failure threshold proposed.

Remaining useful life prediction based on nonlinear random coefficient regression model with fusing failure time data

Remaining useful life(RUL) prediction is one of the most crucial elements in prognostics and health management(PHM). Aiming at the imperfect prior information, this paper proposes an RUL prediction method based on a nonlinear random coefficient regression(RCR) model with fusing failure time data.Firstly, some interesting natures of parameters estimation based on the nonlinear RCR model are given. Based on these natures,the failure time data can be fused as the prior information reasonably. Specifically, the fixed parameters are calculated by the field degradation data of the evaluated equipment and the prior information of random coefficient is estimated with fusing the failure time data of congeneric equipment. Then, the prior information of the random coefficient is updated online under the Bayesian framework, the probability density function(PDF) of the RUL with considering the limitation of the failure threshold is performed. Finally, two case studies are used for experimental verification. Compared with the traditional Bayesian method, the proposed method can effectively reduce the influence of imperfect prior information and improve the accuracy of RUL prediction.

Prognostics and Remaining Useful Life Prediction of Machinery:Advances,Opportunities,and Challenges

As the fundamental and key technique to ensure the safe and reliable operation of vital systems,prognostics with an emphasis on the remaining useful life(RUL)prediction has attracted great attention in the last decades.In this paper,we briefly discuss the general idea and advances of various prognostics and RUL prediction methods for machinery,mainly including data-driven methods,physics-based methods,hybrid methods,etc.Based on the observations fromthe state of the art,we provide comprehensive discussions on the possible opportunities and challenges of prognostics and RUL prediction of machinery so as to steer the future development.

Development of remaining life prediction of crankshaft remanufacturing core

This paper reviewed the main research work in the field of remaining life prediction of crankshaft remanufacturing core by Science and Technology on Remanu- facturing Laboratory. Based on the results of finite element analysis, the R angle zone of crankshaft was determined as a major measuring position. A special measuring probe is developed, and bending fatigue bench tests were carried out to collect electromagnetic damage information during fatigue process. A neural network model was established to identify damage degree of crankshaft core, and a damage evaluation equipment for crankshaft core was developed.

Prediction Method Study on the Remaining Useful Life of Plant New Varieties Rights Based on Weibull Survival Function and Gaussian Model——Taking Hybrid Rice Variety for Example

In view of the difficulty in determining remaining useful life of plant new variety right in economic analysis, Weibull Survival Analysis Method and Gaussian Model to were used to study how to accurately estimate the remaining useful life of plant new variety right. The results showed that the average life of the granted rice varieties was 10.013 years. With the increase of the age of plant variety rights, the probability of the same residual life Ttreaching x was smaller and smaller, the reliability lower and lower, while the probability of the variety rights becoming invalid became greater. The remaining useful life of a specific granted rice variety was closely related to the demonstration promotion age when the granted rice variety reached its maximum area and the appearance of alternative varieties, and when the demonstration promotion age of the granted rice variety reaching the one with the maximum area, the promotion area would be decreased once a new alternative variety appeared, correspondingly with the shortening of the remaining useful life of the variety. Therefore, Weibull Survival Analysis Method and Gaussian Model could describe the remaining useful life＇s time trend, as well as determine the remaining useful life of a concrete plant variety right, clarify the entire life time of varieties rights, and make the economic analysis of plant new varieties rights more accurate and reasonable.

SIGMAPLUG—A NEW TEMPERATURE INDICATOR FOR REMAINING LIFE ASSESSMENT OF HIGH TEMPERATURE COMPONENTS

Improved life assessment techniques will enable engineering components to be replaced before failure, thereby reducing the risk of industrial accidents as well as minimizing financial loss due to unscheduled outages. For components operating at high temperatures, temperature measurement is very important. In many situations, the environmental conditions are too hostile for conventional techniques to be used. Researchers over the world have been looking for new techniques for temperature measurement and one such device, called Feroplug, has been developed previously by the and coworkers. The Feroplug has been patented in USA, UK and Europe by the British Technology Group. The underlying principle of the Feroplug is based on the transformation of ferrite in some specially designed duplex stainless steels. This paper describes a new invention called Sigmaplug which is a new development of the Feroplug but using an entirely different physical principle. It was discovered that the sigma phase in Fe

THE REMAINING LIFE EVALUATION BASED ON THE STRAIN RANGE PARTITIONING APPROACH

The two procedures based on the strain range partitioning approach are proposed for evaluating the remaining life by measuring the surface crack length. Both the procedures require that the material parameters describing the creepfatigue damage rule built and modified by the s and the strain waveform applied have been clarified before the evaluation. One of the procedures can be used only when the total number of the operation cycles n are known, whereas the other is useful even when n is unknown, though it needs the additional crack length measurement. In the latter the surface crack length must be measured not only at n but also at n+n, where n is a given interval of cycles. The results of their application to Mod.9Cr1Mo and 316LC steel smooth specimens subjected to the IJ type creepfatigue loading are shown.

A TimeImageNet Sequence Learning for Remaining Useful Life Estimation of Turbofan Engine in Aircraft Systems

Internet of Things systems generate a large amount of sensor data that needs to be analyzed for extracting useful insights on the health status of the machine under consideration.Sensor data of all possible states of a system are used for building machine learning models.These models are further used to predict the possible downtime for proactive action on the system condition.Aircraft engine data from run to failure is used in the current study.The run to failure data includes states like new installation,stable operation,first reported issue,erroneous operation,and final failure.In the present work,the non-linear multivariate sensor data is used to understand the health status and anomalous behavior.The methodology is based on different sampling sizes to obtain optimum results with great accuracy.The time series of each sensor is converted to a 2D image with a specific time window.Converted Images would represent the health of a system in higher-dimensional space.The created images were fed to Convolutional Neural Network,which includes both time variation and space variation of each sensed parameter.Using these created images,a model for estimating the remaining life of the aircraft is developed.Further,the proposed net is also used for predicting the number of engines that would fail in the given time window.The current methodology is useful in avoiding the health index generation for predicting the remaining useful life of the industrial components.Better accuracy in the classification of components is achieved using the TimeImagenet-based approach.

Remaining useful life estimation based on Wiener degradation processes with random failure threshold

Remaining useful life(RUL) estimation based on condition monitoring data is central to condition based maintenance(CBM). In the current methods about the Wiener process based RUL estimation, the randomness of the failure threshold has not been studied thoroughly. In this work, by using the truncated normal distribution to model random failure threshold(RFT), an analytical and closed-form RUL distribution based on the current observed data was derived considering the posterior distribution of the drift parameter. Then, the Bayesian method was used to update the prior estimation of failure threshold. To solve the uncertainty of the censored in situ data of failure threshold, the expectation maximization(EM) algorithm is used to calculate the posteriori estimation of failure threshold. Numerical examples show that considering the randomness of the failure threshold and updating the prior information of RFT could improve the accuracy of real time RUL estimation.

Reliability estimation and remaining useful lifetime prediction for bearing based on proportional hazard model

As the central component of rotating machine,the performance reliability assessment and remaining useful lifetime prediction of bearing are of crucial importance in condition-based maintenance to reduce the maintenance cost and improve the reliability.A prognostic algorithm to assess the reliability and forecast the remaining useful lifetime(RUL) of bearings was proposed,consisting of three phases.Online vibration and temperature signals of bearings in normal state were measured during the manufacturing process and the most useful time-dependent features of vibration signals were extracted based on correlation analysis(feature selection step).Time series analysis based on neural network,as an identification model,was used to predict the features of bearing vibration signals at any horizons(feature prediction step).Furthermore,according to the features,degradation factor was defined.The proportional hazard model was generated to estimate the survival function and forecast the RUL of the bearing(RUL prediction step).The positive results show that the plausibility and effectiveness of the proposed approach can facilitate bearing reliability estimation and RUL prediction.