The tribological behavior can be informative about the incipient faults of robot manipulators. This study explores the evolution of friction characteristics from cold start to thermal equilibrium through a series of steady-state friction experiments. Based on these experimental observations, a friction-based fault diagnosis framework is proposed. The fault diagnosis process primarily involves defining the healthy state, decomposing friction curves and their features, and anomaly detection. Given the dependence of friction characteristics on different sources of faults, the parameters of steady-state experimental friction model are divided into two categories: one associated with contact interactions and the other related to non-contact regimes. Subsequently, confidence regions corresponding to distinguishable friction characteristics are independently constructed. These regions encapsulate the statistical description of the healthy state, characterized by mean values and the covariance of the friction characteristic parameter vectors during the unloaded state. In addition, we conduct experiments that consider the influence of applied loads on friction behavior. These experiments serve as a test set for comparison against nominal statistics. Leveraging the similarity between the effects of wear and load on friction, we introduce equivalent load thresholds to assess the severity of joint degradation. The results demonstrate the feasibility of employing confidence region views based on friction characteristic classification for fault detection and isolation.

Sensed data from high-value engineering systems is being increasingly exploited to optimise their operation and maintenance. In aerospace, returning all measured data to a central repository is prohibitively expensive, often causing useful, high-value data to be discarded. The ability to detect, prioritise and return useful data on asset and in real-time is vital to move toward more sustainable maintenance activities.

We present a data-driven solution for on-line detection and prioritisation of anomalous data that is centrally processed and used to update individualised digital twins (DT) distributed onto remote machines. The DT is embodied as a convolutional neural network (CNN) optimised for real-time execution on a resource constrained gas turbine monitoring computer. The CNN generates a state prediction with uncertainty, which is used as a metric to select informative data for transfer to a remote fleet monitoring system. The received data is screened for faults before updating the weights on the CNN, which are synchronised between real and virtual asset.

Results show the successful detection of a known in-flight engine fault and the collection of data related to high novelty pre-cursor events that were previously unrecognised. We demonstrate that data related to novel operation are also identified for transfer to the fleet monitoring system, allowing model improvement by retraining. In addition to these industrial dataset results, reproducible examples are provided for a public domain NASA dataset.

The data prioritisation solution is capable of running in real-time on production-standard low-power embedded hardware and is deployed on the Rolls-Royce Pearl 15 engines.

As an important index to quantitatively measure the motion performance of a manipulator, motion reliability is affected by many factors, such as joint clearance. The present research utilized a UR10 manipulator as the research object. A factor mapping model for influencing the motion reliability was established. The link flexibility factor, joint flexibility factor, joint clearance factor, and Denavit–Hartenberg (DH) parameters were comprehensively considered in this model. The coupling relationship among the various factors was concisely expressed. Subsequently, the nonlinear response surface method was used to calculate the reliability and sensitivity of the manipulator, which provided an applicable reference for its trajectory planning and motion control. In addition, a data-driven fault diagnosis method based on the kernel principal component analysis (KPCA) was used to verify the motion accuracy and sensitivity of the manipulator, and joint rotation failure was considered as an example to verify the accuracy of the KPCA method. This study on the motion reliability of the manipulator is of great significance for the current motion performance, adjusting the control strategy and optimizing the completion effect of the motion task of a manipulator.

A data-driven approach for multiclass fault diagnosis of drive fed induction motor (IM) using stator current at steady-state condition is a complex pattern classification problem. The applied DWT-IDWT algorithm in this work is reinforced by a novel selection criterion for mother wavelet application and justifies the originality of the work. This investigation has exploited the built-in feature selection process of Random Forest (RF) classifier to resolve the most challenging issues in this area, including bearing and stator fault detection. RF has shown an outstanding performance without application of any feature selection technique because of its distributive feature model. The robustness of the results backed by the experimental verification shows an encouraging future of RF as a classifier in the area of intelligent fault diagnosis of IM.

This paper considers actuator redundancy management for a redundant multirotor Unmanned Aerial Vehicle (UAV) under actuators failures. Different approaches are proposed: using robust control (passive fault tolerance), and reconfigurable control (active fault tolerance). The robust controller is designed using high-order super-twisting sliding mode techniques, and handles the failures without requiring information from a Fault Detection scheme. The Active Fault-Tolerant Control (AFTC) is achieved through redistributing the control signals among the healthy actuators using reconfigurable multiplexing and pseudo-inverse control allocation. The Fault Detection and Isolation problem is also considered by proposing model-based and model-free modules. The proposed techniques are all implemented on a coaxial octorotor UAV. Different experiments with different scenarios were conducted for the validation of the proposed strategies. Finally, advantages, disadvantages, application considerations and limitations of each method are examined through quantitative and qualitative studies.

This work deals with the application of the fuzzy logic to automate diagnosis of bearing defects in rotating machines based on vibration signals. The classification tool used is a fuzzy inference system (FIS) of Mamdani type. The vector form of input contains parameters extracted from the signals collected from the test bench studied. The output vector contains the classes for the different operating modes of the experimental study. The results show that; pretreatment data (filtering, decimation,...), the choice of parameters of fuzzy inference system (input variables and output, types and parameters of membership functions associated with different input and output variables of the system, the generation of fuzzy inference rules,...) are of major importance for the performance of fuzzy inference system used as a tool for fault diagnosis of rotating machinery.

Fault diagnosis plays an important role in the operation of modern robotic systems. A number of researchers have proposed fault diagnosis architectures for robotic manipulators using the model-based analytical redundancy approach. One of the key issues in the design of such fault diagnosis schemes is the effect of modeling uncertainties on their performance. This paper investigates the problem of fault diagnosis in rigid-link robotic manipulators with modeling uncertainties. A learning architecture with sigmoidal neural networks is used to monitor the robotic system for off-nominal behavior due to faults. The robustness, sensitivity, missed detection and stability properties of the fault diagnosis scheme are rigorously established. Simulation examples are presented to illustrate the ability of the neural network based robust fault diagnosis scheme to detect and accommodate faults in a two-link robotic manipulator.

Modern industry is concerned about extending the lifetime of its critical processes and maintaining them only when required. Significant aspects of these trends include the ability to diagnose impending failures, prognosticate the remaining useful lifetime of the process and schedule maintenance operations so that uptime is maximized. Prognosis is probably the most difficult of the three issues leading to condition-based maintenance (CBM). This paper attempts to address this challenging problem with intelligence-oriented techniques, specifically dynamic wavelet neural networks (DWNNs). DWNNs incorporate temporal information and storage capacity into their functionality so that they can predict into the future, carrying out fault prognostic tasks. Such fundamental issues as the network structure, learning algorithms, stability analysis, uncertainty management, and performance assessment are studied in a theoretical framework. An example is presented in which a trained DWNN successfully prognoses a defective bearing with a crack in its inner race.

Traditional expert systems for fault diagnosis have a bottleneck in knowledge acquisition, and have limitations in knowledge representation and reasoning. A new expert system shell for fault diagnosis is presented in this paper to develop multiple knowledge models (object model, rules, neural network, case-base and diagnose models) hierarchically based on multiple knowledge. The structure of the expert system shell and the knowledge representation of multiple models are described. Diagnostic algorithms are presented for automatic modeling and hierarchical reasoning. It will be shown that the expert system shell is very effective in building diagnostic expert systems.

This paper presents a methodology for assessment of diagnosability of mechanical and hydraulic systems. The method is developed on the basis of relationships between system performance parameters and physical objects, that is, components of the system. These relationships are identified by system functional domain and are modeled in terms of a bipartite graph, called Diagnosability Bipartite Graph (DBG). A matrix called Diagnosability Matrix (DM) represents the DBG. Various diagnosability parameters of the system are derived from the DBG and the DM and these are useful in evaluation and comparison of design variants of the system. These parameters: are maximum number of set conflicts (MNS), maximum number of components in a set conflict (MNCS), diagnosability effort and cost (DEC), and average merit of diagnosability (AMD). The design having the lowest value of MNCS, AMD, and DEC; and highest value of MNS has the highest diagnosability. On the basis of these, a best design alternative is selected from diagnosability point of view. Moreover, components, which have poor diagnosability, are also identified. Maximum number of set conflicts (MNS) also guides in system fault diagnosis. The proposed procedure aids in the design and development of maintainable systems from diagnosability consideration. The method can also be used for evaluating and comparing the diagnosability of the systems. This method is illustrated with the help of two examples.