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NASA NTRS1987

A flight expert system (FLES) for on-board fault monitoring and diagnosis

The increasing complexity of modern aircraft creates a need for a larger number of caution and warning devices. But more alerts require more memorization and higher workloads for the pilot and tend to induce a higher probability of errors. Therefore, an architecture for a flight expert system (FLES) is developed to assist pilots in monitoring, diagnosing and recovering from in-flight faults. A prototype of FLES has been implemented. A sensor simulation model was developed and employed to provide FLES with airplane status information during the diagnostic process. The simulator is based on the Lockheed Advanced Concept System (ACS), a future generation airplane, and on the Boeing 737. A distinction between two types of faults, maladjustments and malfunctions, has led to two approaches to fault diagnosis. These approaches are evident in two FLES subsystems: the flight phase monitor and the sensor interrupt handler. The specific problem addressed in these subsystems has been that of integrating information received from multiple sensors with domain knowledge in order to access abnormal situations during airplane flight. Malfunctions and maladjustments are handled separately, diagnosed using domain knowledge.

Ali, Moonis↗

NASA NTRS1990

StarPlan: A model-based diagnostic system for spacecraft

The Sunnyvale Division of Ford Aerospace created a model-based reasoning capability for diagnosing faults in space systems. The approach employs reasoning about a model of the domain (as it is designed to operate) to explain differences between expected and actual telemetry; i.e., to identify the root cause of the discrepancy (at an appropriate level of detail) and determine necessary corrective action. A development environment, named Paragon, was implemented to support both model-building and reasoning. The major benefit of the model-based approach is the capability for the intelligent system to handle faults that were not anticipated by a human expert. The feasibility of this approach for diagnosing problems in a spacecraft was demonstrated in a prototype system, named StarPlan. Reasoning modules within StarPlan detect anomalous telemetry, establish goals for returning the telemetry to nominal values, and create a command plan for attaining the goals. Before commands are implemented, their effects are simulated to assure convergence toward the goal. After the commands are issued, the telemetry is monitored to assure that the plan is successful. These features of StarPlan, along with associated concerns, issues and future directions, are discussed.

Heher, Dennis↗

NASA NTRS2004

Transient Region Coverage in the Propulsion IVHM Technology Experiment

Over the last several years researchers at NASA Glenn and Ames Research Centers have developed a real-time fault detection and isolation system for propulsion subsystems of future space vehicles. The Propulsion IVHM Technology Experiment (PITEX), as it is called follows the model-based diagnostic methodology and employs Livingstone, developed at NASA Ames, as its reasoning engine. The system has been tested on,flight-like hardware through a series of nominal and fault scenarios. These scenarios have been developed using a highly detailed simulation of the X-34 flight demonstrator main propulsion system and include realistic failures involving valves, regulators, microswitches, and sensors. This paper focuses on one of the recent research and development efforts under PITEX - to provide more complete transient region coverage. It describes the development of the transient monitors, the corresponding modeling methodology, and the interface software responsible for coordinating the flow of information between the quantitative monitors and the qualitative, discrete representation Livingstone.

Balaban, Edward↗

NASA NTRS2011

Vehicle Integrated Prognostic Reasoner (VIPR) 2010 Annual Final Report

Honeywell's Central Maintenance Computer Function (CMCF) and Aircraft Condition Monitoring Function (ACMF) represent the state-of-the art in integrated vehicle health management (IVHM). Underlying these technologies is a fault propagation modeling system that provides nose-to-tail coverage and root cause diagnostics. The Vehicle Integrated Prognostic Reasoner (VIPR) extends this technology to interpret evidence generated by advanced diagnostic and prognostic monitors provided by component suppliers to detect, isolate, and predict adverse events that affect flight safety. This report describes year one work that included defining the architecture and communication protocols and establishing the user requirements for such a system. Based on these and a set of ConOps scenarios, we designed and implemented a demonstration of communication pathways and associated three-tiered health management architecture. A series of scripted scenarios showed how VIPR would detect adverse events before they escalate as safety incidents through a combination of advanced reasoning and additional aircraft data collected from an aircraft condition monitoring system. Demonstrating VIPR capability for cases recorded in the ASIAS database and cross linking them with historical aircraft data is planned for year two.

Hadden, George D.↗

NASA NTRS2009

Software Health Management: A Short Review of Challenges and Existing Techniques

Modern spacecraft (as well as most other complex mechanisms like aircraft, automobiles, and chemical plants) rely more and more on software, to a point where software failures have caused severe accidents and loss of missions. Software failures during a manned mission can cause loss of life, so there are severe requirements to make the software as safe and reliable as possible. Typically, verification and validation (V&V) has the task of making sure that all software errors are found before the software is deployed and that it always conforms to the requirements. Experience, however, shows that this gold standard of error-free software cannot be reached in practice. Even if the software alone is free of glitches, its interoperation with the hardware (e.g., with sensors or actuators) can cause problems. Unexpected operational conditions or changes in the environment may ultimately cause a software system to fail. Is there a way to surmount this problem? In most modern aircraft and many automobiles, hardware such as central electrical, mechanical, and hydraulic components are monitored by IVHM (Integrated Vehicle Health Management) systems. These systems can recognize, isolate, and identify faults and failures, both those that already occurred as well as imminent ones. With the help of diagnostics and prognostics, appropriate mitigation strategies can be selected (replacement or repair, switch to redundant systems, etc.). In this short paper, we discuss some challenges and promising techniques for software health management (SWHM). In particular, we identify unique challenges for preventing software failure in systems which involve both software and hardware components. We then present our classifications of techniques related to SWHM. These classifications are performed based on dimensions of interest to both developers and users of the techniques, and hopefully provide a map for dealing with software faults and failures.

Pipatsrisawat, Knot↗

NASA NTRS2005

Lessons Learned in the Livingstone 2 on Earth Observing One Flight Experiment

The Livingstone 2 (L2) model-based diagnosis software is a reusable diagnostic tool for monitoring complex systems. In 2004, L2 was integrated with the JPL Autonomous Sciencecraft Experiment (ASE) and deployed on-board Goddard's Earth Observing One (EO-1) remote sensing satellite, to monitor and diagnose the EO-1 space science instruments and imaging sequence. This paper reports on lessons learned from this flight experiment. The goals for this experiment, including validation of minimum success criteria and of a series of diagnostic scenarios, have all been successfully net. Long-term operations in space are on-going, as a test of the maturity of the system, with L2 performance remaining flawless. L2 has demonstrated the ability to track the state of the system during nominal operations, detect simulated abnormalities in operations and isolate failures to their root cause fault. Specific advances demonstrated include diagnosis of ambiguity groups rather than a single fault candidate; hypothesis revision given new sensor evidence about the state of the system; and the capability to check for faults in a dynamic system without having to wait until the system is quiescent. The major benefits of this advanced health management technology are to increase mission duration and reliability through intelligent fault protection, and robust autonomous operations with reduced dependency on supervisory operations from Earth. The work-load for operators will be reduced by telemetry of processed state-of-health information rather than raw data. The long-term vision is that of making diagnosis available to the onboard planner or executive, allowing autonomy software to re-plan in order to work around known component failures. For a system that is expected to evolve substantially over its lifetime, as for the International Space Station, the model-based approach has definite advantages over rule-based expert systems and limit-checking fault protection systems, as these do not scale well. The model-based approach facilitates reuse of the L2 diagnostic software; only the model of the system to be diagnosed and telemetry monitoring software has to be rebuilt for a new system or expanded for a growing system. The hierarchical L2 model supports modularity and expendability, and as such is suitable solution for integrated system health management as envisioned for systems-of-systems.

Hayden, Sandra C.↗

NASA NTRS2016

NASA Space Flight Vehicle Fault Isolation Challenges

The Space Launch System (SLS) is the new NASA heavy lift launch vehicle and is scheduled for its first mission in 2017. The goal of the first mission, which will be uncrewed, is to demonstrate the integrated system performance of the SLS rocket and spacecraft before a crewed flight in 2021. SLS has many of the same logistics challenges as any other large scale program. Common logistics concerns for SLS include integration of discrete programs geographically separated, multiple prime contractors with distinct and different goals, schedule pressures and funding constraints. However, SLS also faces unique challenges. The new program is a confluence of new hardware and heritage, with heritage hardware constituting seventy-five percent of the program. This unique approach to design makes logistics concerns such as testability of the integrated flight vehicle especially problematic. The cost of fully automated diagnostics can be completely justified for a large fleet, but not so for a single flight vehicle. Fault detection is mandatory to assure the vehicle is capable of a safe launch, but fault isolation is another issue. SLS has considered various methods for fault isolation which can provide a reasonable balance between adequacy, timeliness and cost. This paper will address the analyses and decisions the NASA Logistics engineers are making to mitigate risk while providing a reasonable testability solution for fault isolation.

Bramon, Christopher↗

DOE OSTI2022

Using discrete Bayesian networks for diagnosing and isolating cross-level faults in HVAC systems

Fault detection and diagnosis (FDD) technologies are critical to ensure satisfactory building performance, such as reducing energy wastes and negative impacts on occupant comfort and productivity. Existing FDD technologies mainly focus on component-level FDD solutions, which could lead to mis-diagnosis of cross-level faults in heating, ventilating, and air-conditioning (HVAC) systems. Cross-level faults are those faults that occur in one component or subsystem, but cause operational abnormalities in other components or subsystems, and result in a building level performance degradation. How to effectively diagnose the root cause of a cross-level fault is the focus of this study. Here, this paper presents a novel discrete Bayesian Network (DisBN)-based method for diagnosing cross-level faults in an HVAC system commonly used in commercial buildings. A two-level DisBN structure model is developed in this study. The parameters used in the DisBN model are obtained either from expert knowledge or through machine-learning strategies from normal system operation data. Meanwhile, the probability parameters are discretized to incorporate the uncertainties associated with typical expert knowledge. Thus, the developed DisBN method addresses the challenges many other BN based FDD methods face, i.e., the lack of fault data for BN parameter training. The developed DisBN represents causal relationships between a fault and its cross-level system impacts (i.e., fault symptoms or fault indicators) by considering how fault impacts propagate across different levels in an HVAC system. A weather and schedule information-based Pattern Matching (WPM) method is employed to automatically create WPM baseline data sets for each incoming real time snapshot data from the building systems. Consequently, BN inference and real-time diagnostics are achieved by comparing incoming snapshot data and the WPM baseline data set. The proposed method is evaluated using experimental fault data collected in a campus building. Fault diagnosis results demonstrate that the WPM-DisBN method is effective at locating the root causes of cross-level faults in an HVAC system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1995

Detecting gear tooth fracture in a high contact ratio face gear mesh

This paper summarized the results of a study in which three different vibration diagnostic methods were used to detect gear tooth fracture in a high contact ratio face gear mesh. The NASA spiral bevel gear fatigue test rig was used to produce unseeded fault, natural failures of four face gear specimens. During the fatigue tests, which were run to determine load capacity and primary failure mechanisms for face gears, vibration signals were monitored and recorded for gear diagnostic purposes. Gear tooth bending fatigue and surface pitting were the primary failure modes found in the tests. The damage ranged from partial tooth fracture on a single tooth in one test to heavy wear, severe pitting, and complete tooth fracture of several teeth on another test. Three gear fault detection techniques, FM4, NA4*, and NB4, were applied to the experimental data. These methods use the signal average in both the time and frequency domain. Method NA4* was able to conclusively detect the gear tooth fractures in three out of the four fatigue tests, along with gear tooth surface pitting and heavy wear. For multiple tooth fractures, all of the methods gave a clear indication of the damage. It was also found that due to the high contact ratio of the face gear mesh, single tooth fractures did not significantly affect the vibration signal, making this type of failure difficult to detect.

Zakrajsek, James J.↗

NASA NTRS2013

Vehicle Integrated Prognostic Reasoner (VIPR) Metric Report

This document outlines a set of metrics for evaluating the diagnostic and prognostic schemes developed for the Vehicle Integrated Prognostic Reasoner (VIPR), a system-level reasoner that encompasses the multiple levels of large, complex systems such as those for aircraft and spacecraft. VIPR health managers are organized hierarchically and operate together to derive diagnostic and prognostic inferences from symptoms and conditions reported by a set of diagnostic and prognostic monitors. For layered reasoners such as VIPR, the overall performance cannot be evaluated by metrics solely directed toward timely detection and accuracy of estimation of the faults in individual components. Among other factors, overall vehicle reasoner performance is governed by the effectiveness of the communication schemes between monitors and reasoners in the architecture, and the ability to propagate and fuse relevant information to make accurate, consistent, and timely predictions at different levels of the reasoner hierarchy. We outline an extended set of diagnostic and prognostics metrics that can be broadly categorized as evaluation measures for diagnostic coverage, prognostic coverage, accuracy of inferences, latency in making inferences, computational cost, and sensitivity to different fault and degradation conditions. We report metrics from Monte Carlo experiments using two variations of an aircraft reference model that supported both flat and hierarchical reasoning.

Cornhill, Dennis↗

DOE OSTI2023

Development of a Scalable Risk-informed Predictive Maintenance Cloud-based Strategy at Nuclear Power Plants

The fact that light-water reactor operation and maintenance costs are prohibitively expensive and contribute to the premature decommissioning of nuclear power plants is partly due to how the equipment is monitored. In recent years, cloud computing has emerged as a dominant technology, as its low cost, computing and storage adaptability, and ability to host applications across numerous virtual infrastructures potentially make it a cost-effective alternative to onsite storage and diagnostics. In this paper, a technological assessment is carried out on a provisional cloud deployment architecture for a nuclear power plant predictive monitoring system. This cloud-based monitoring system would enable maintenance and diagnostic analysts and other authorized plant users to remotely monitor equipment functionality, thus enabling early fault detection and effective predictive maintenance practices. To provide data processing and storage, sensor device networking, and database management, the Microsoft Azure cloud platform is utilized as part of the proposed cloud architecture; however, this analysis could be extended to other cloud computing service providers as well. The focus of this paper is on application of cloud resources for enabling predictive maintenance, identification of technological hurdles associated with moving to a cloud-computing-based architecture, and potential benefits from moving to a centralized cloud system.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2013

An Efficient Model-based Diagnosis Engine for Hybrid Systems Using Structural Model Decomposition

Complex hybrid systems are present in a large range of engineering applications, like mechanical systems, electrical circuits, or embedded computation systems. The behavior of these systems is made up of continuous and discrete event dynamics that increase the difficulties for accurate and timely online fault diagnosis. The Hybrid Diagnosis Engine (HyDE) offers flexibility to the diagnosis application designer to choose the modeling paradigm and the reasoning algorithms. The HyDE architecture supports the use of multiple modeling paradigms at the component and system level. However, HyDE faces some problems regarding performance in terms of complexity and time. Our focus in this paper is on developing efficient model-based methodologies for online fault diagnosis in complex hybrid systems. To do this, we propose a diagnosis framework where structural model decomposition is integrated within the HyDE diagnosis framework to reduce the computational complexity associated with the fault diagnosis of hybrid systems. As a case study, we apply our approach to a diagnostic testbed, the Advanced Diagnostics and Prognostics Testbed (ADAPT), using real data.

Structural Decomposition↗

NASA NTRS2011

Feature Acquisition with Imbalanced Training Data

This work considers cost-sensitive feature acquisition that attempts to classify a candidate datapoint from incomplete information. In this task, an agent acquires features of the datapoint using one or more costly diagnostic tests, and eventually ascribes a classification label. A cost function describes both the penalties for feature acquisition, as well as misclassification errors. A common solution is a Cost Sensitive Decision Tree (CSDT), a branching sequence of tests with features acquired at interior decision points and class assignment at the leaves. CSDT's can incorporate a wide range of diagnostic tests and can reflect arbitrary cost structures. They are particularly useful for online applications due to their low computational overhead. In this innovation, CSDT's are applied to cost-sensitive feature acquisition where the goal is to recognize very rare or unique phenomena in real time. Example applications from this domain include four areas. In stream processing, one seeks unique events in a real time data stream that is too large to store. In fault protection, a system must adapt quickly to react to anticipated errors by triggering repair activities or follow- up diagnostics. With real-time sensor networks, one seeks to classify unique, new events as they occur. With observational sciences, a new generation of instrumentation seeks unique events through online analysis of large observational datasets. This work presents a solution based on transfer learning principles that permits principled CSDT learning while exploiting any prior knowledge of the designer to correct both between-class and withinclass imbalance. Training examples are adaptively reweighted based on a decomposition of the data attributes. The result is a new, nonparametric representation that matches the anticipated attribute distribution for the target events.

Thompson, David R.↗

NASA NTRS2020

Development of a Supervisory Tool for Fault Detection and Diagnosis of DC Electric Power Systems with the Application of Deep Space Vehicles

This dissertation formulates the problem of fault detection and diagnosis of DC electric power systems for the application of autonomous spacecraft. The ability to accurately identify and isolate failures in the electrical power system is critical to ensure the reliability of a spacecraft. This problem becomes more pronounced during deep space missions that lack the ability to monitor from ground control. The current state of electrical power system fault supervision is insufficient to guarantee highly reliable and robust operation. To solve this issue, a combination of model-based and rules-based techniques are used in a hierarchical framework to improve the diagnostic performance of the spacecraft electrical power system. Noise, disturbances, and modeling errors are considered in the design of the method. Practical considerations related to the hardware and software are discussed for the flight application. A wide array of failure types are simulated in a series of experiments to assess the functionality of the design. The experiments showed that the methods used improved the diagnostic capability of the autonomous system while taking into account the limitations attributed to flight software requirements. The significance of this study is to provide a framework capable of advanced diagnostics of an electrical power system with little to no interaction from a human operator.

Fault Detection and Diagnosis↗

NASA NTRS1986

A flight expert system (FLES) for on-board fault monitoring and diagnosis

The increasing complexity of modern aircraft creates a need for a larger number of caution and warning devices. But more alerts require more memorization and higher work loads for the pilot and tend to induce a higher probability of errors. Therefore, an architecture for a flight expert system (FLES) to assist pilots in monitoring, diagnosing and recovering from in-flight faults has been developed. A prototype of FLES has been implemented. A sensor simulation model was developed and employed to provide FLES with the airplane status information during the diagnostic process. The simulator is based partly on the Lockheed Advanced Concept System (ACS), a future generation airplane, and partly on the Boeing 737, an existing airplane. A distinction between two types of faults, maladjustments and malfunctions, has led us to take two approaches to fault diagnosis. These approaches are evident in two FLES subsystems: the flight phase monitor and the sensor interrupt handler. The specific problem addressed in these subsystems has been that of integrating information received from multiple sensors with domain knowledge in order to assess abnormal situations during airplane flight. This paper describes the reasons for handling malfunctions and maladjustments separately and the use of domain knowledge in the diagnosis of each.

Ali, M.↗

NASA NTRS2018

Self Diagnostic Accelerometer Field Programmable Gate Array (SDA FPGA)

A self-diagnostic accelerometer (SDA) field programmable gate array (FPGA) may be capable of real time or near-real time diagnostic processing to determine potential accelerometer issues during flight or other mission critical operational situations. The SDA FPGA may determine accelerometer structural health and an attachment condition using an electronics system that is smaller, more energy efficient, and more cost effective than previous diagnostic tools. Advantages of the system may include diagnosing sensors automatically, immediately, actively (i.e., confirming the fault), and consistently, without the influence of a human operator. Customizable SDA algorithms may be adjusted to the specific needs of the sensor/environment.

Tokars, Roger P.↗

NASA NTRS2010

Portable Health Algorithms Test System

A document discusses the Portable Health Algorithms Test (PHALT) System, which has been designed as a means for evolving the maturity and credibility of algorithms developed to assess the health of aerospace systems. Comprising an integrated hardware-software environment, the PHALT system allows systems health management algorithms to be developed in a graphical programming environment, to be tested and refined using system simulation or test data playback, and to be evaluated in a real-time hardware-in-the-loop mode with a live test article. The integrated hardware and software development environment provides a seamless transition from algorithm development to real-time implementation. The portability of the hardware makes it quick and easy to transport between test facilities. This hard ware/software architecture is flexible enough to support a variety of diagnostic applications and test hardware, and the GUI-based rapid prototyping capability is sufficient to support development execution, and testing of custom diagnostic algorithms. The PHALT operating system supports execution of diagnostic algorithms under real-time constraints. PHALT can perform real-time capture and playback of test rig data with the ability to augment/ modify the data stream (e.g. inject simulated faults). It performs algorithm testing using a variety of data input sources, including real-time data acquisition, test data playback, and system simulations, and also provides system feedback to evaluate closed-loop diagnostic response and mitigation control.

Melcher, Kevin J.↗

NASA NTRS1985

Sensor-based fault diagnosis in a flight expert system

A prototype of a knowledge-based flight expert system (FLES) has been developed to assist airplane pilots in monitoring, analyzing, and diagnosing faults and to provide support in reducing the pilot's own mistakes. A sensor simulation model has been developed to provide FLES with the airplane status information during the diagnostic process. The simulator is based partly on the Advanced Concept System (ACS), a future-generation airplane, and partly on the Boeing 737, an existing airplane. The architecture of FLES contains several subsystems. One of the major subsystems performs fault diagnosis in the electrical system of the ACS. This paper describes the mechanism and functionality of the automatic diagnosis performed in this expert system.

Ali, M.↗