The full potential of predictive maintenance has not yet been utilised. Current solutions focus on individual steps of the predictive maintenance cycle and only work for very specific settings. The overarching challenge of predictive maintenance is to leverage these individual building blocks to obtain a framework that supports optimal maintenance and asset management. The PrimaVera project has identified four obstacles to tackle in order to utilise predictive maintenance at its full potential: lack of orchestration and automation of the predictive maintenance workflow, inaccurate or incomplete data and the role of human and organisational factors in data-driven decision support tools. Furthermore, an intuitive generic applicable predictive maintenance process model is presented in this paper to provide a structured way of deploying predictive maintenance solutions https://doi.org/10.3390/app10238348 LinkedIn: https://www.linkedin.com/in/john-bolte-0856134/
The full potential of predictive maintenance has not yet been utilised. Current solutions focus on individual steps of the predictive maintenance cycle and only work for very specific settings. The overarching challenge of predictive maintenance is to leverage these individual building blocks to obtain a framework that supports optimal maintenance and asset management. The PrimaVera project has identified four obstacles to tackle in order to utilise predictive maintenance at its full potential: lack of orchestration and automation of the predictive maintenance workflow, inaccurate or incomplete data and the role of human and organisational factors in data-driven decision support tools. Furthermore, an intuitive generic applicable predictive maintenance process model is presented in this paper to provide a structured way of deploying predictive maintenance solutions.
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Data-driven condition-based maintenance (CBM) and predictive maintenance (PdM) strategies have emerged over recent years and aim at minimizing the aviation maintenance costs and environmental impact by the diagnosis and prognosis of aircraft systems. As the use of data and relevant algorithms is essential to AI-based gas turbine diagnostics, there are different technical, operational, and regulatory challenges that need to be tackled in order for the aeronautical industry to be able to exploit their full potential. In this work, the machine learning (ML) method of the generalised additive model (GAM) is used in order to predict the evolution of an aero engine’s exhaust gas temperature (EGT). Three different continuous synthetic data sets developed by NASA are employed, known as New Commercial Modular Aero-Propulsion System Simulation (N-CMAPSS), with increasing complexity in engine deterioration. The results show that the GAM can be predict the evolution of the EGT with high accuracy when using several input features that resemble the types of physical sensors installed in aero gas turbines currently in operation. As the GAM offers good interpretability, this case study is used to discuss the different data attributes a data set needs to have in order to build trust and move towards certifiable models in the future.
Rotating machinery, such as centrifugal pumps, turbines, bearings, and other critical systems, is the backbone of various industrial processes. Their failures can lead to significant maintenance costs and downtime. To ensure their continuous operation, we propose a fault diagnosis and monitoring framework that leverages the innovative use of acoustic sensors for early fault detection, especially in components less accessible for traditional vibration-based monitoring strategies. The main objective of the proposed project is to develop a fault diagnosis and monitoring framework for rotating machinery, including the fusion of acoustic sensors and physics-based models. By combining real-time monitoring data from acoustic sensors with an understanding of first principles, the framework will enable maintenance practitioners to identify and categorize different failure modes such as wear, fatigue, cavitation, reduced flow, bearing damage, impeller damage, misalignment, etc. In the initial phase, the focus will be on centrifugal pumps using the existing test set-up at the University of Twente. Sorama specializes in acoustic sensors to locate noise sources and will provide acoustic cameras to capture sound patterns related to pump deterioration during various operating conditions. These acoustic signals will then be correlated with the different failure modes and mechanisms that will be described by physics-based models, such as wear, fatigue, cavitation, corrosion, etc. Furthermore, a recently published data set by the Dynamics Based Maintenance research group that includes vibration analysis data and motor current analysis data of various fault scenarios, such as mentioned above, will be used as validation. The anticipated outcome of this project is a versatile framework for a physics-informed acoustic monitoring system. This system is designed to enhance early fault detection significantly, reducing maintenance costs and downtime across a broad spectrum of industrial applications, from centrifugal pumps to turbines, bearings, and beyond.
