Method for predictive maintenance of a machine

• US 20070088550A1
• Filed: 10/13/2005
• Published: 04/19/2007
• Est. Priority Date: 10/13/2005
• Status: Abandoned Application

• Current Assignee: Ford Motor Company
• Original Assignee: Ford Motor Company
• Inventors: Tseng, Fling, Filev, Dimitar, Chesney, Dave, Farquhar, Gary, Hamidieh, Youssef, Baruah, Pundarikaksha, Chinnam, Ratna
• Application Number:
  US11/249,601
• Publication Number:
  US 20070088550A1
• Time in Patent Office: Days
• US Class Current: 704/245
• CPC Class Codes: G05B 23/0221 Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06
• CPC Class Codes: G06F 18/10 Pre-processing; Data cleansing

Abstract

A method for predictive maintenance of a machine includes collecting feature data for the machine which includes a plurality of feature vectors. At least some of the feature vectors are standardized to facilitate compatibility between different vectors. At least some of the standardized feature vectors are transformed into corresponding two-dimensional feature vectors. At least some of the two-dimensional feature vectors are clustered together based on operating modes of the machine. Similar steps are performed on additional feature data collected from the machine. Recently gathered two-dimensional feature vectors are compared to previously clustered feature vectors to provide predictive maintenance information for the machine.

Claims

1. A method for predictive maintenance of a machine, the method comprising:

collecting data related to operation of the machine;

transforming at least some of the data into feature vectors in a first feature space;

standardizing at least some of the feature vectors, thereby creating standardized feature vectors in a standardized feature space;

transforming at least some of the standardized feature vectors into two-dimensional feature vectors in a two-dimensional feature space;

clustering at least some of the two-dimensional feature vectors based on similarity between the two-dimensional feature vectors, thereby forming at least one two-dimensional vector cluster;

collecting additional data related to operation of the machine;

transforming at least some of the additional data into additional feature vectors in the first feature space;

standardizing at least some of the additional feature vectors, thereby creating additional standardized feature vectors in the standardized feature space;

transforming at least some of the additional standardized feature vectors into additional two-dimensional feature vectors in the two-dimensional feature space; and

analyzing at least some of the additional two-dimensional feature vectors relative to the at least one two-dimensional vector cluster to provide predictive maintenance information for the machine.

2. The method of claim 1, wherein the clustering of at least some of the two-dimensional feature vectors includes forming a cluster based on an operating mode of the machine, and further includes forming, within the operating mode cluster, a cluster based on an operating condition of the machine, the operating condition occurring while the machine is operating in the operating mode.

3. The method of claim 2, wherein analyzing at least some of the additional two-dimensional feature vectors includes updating the operating condition cluster to determine a movement of the operating condition cluster toward a boundary of the operating mode cluster, thereby facilitating a determination of a future anomaly in the operation of the machine.

4. The method of claim 1, further comprising clustering at least some of the standardized feature vectors based on similarity between the standardized feature vectors, thereby forming at least one standardized vector cluster.

5. The method of claim 4, wherein the clustering of at least some of the standardized feature vectors includes forming a cluster based on an operating mode of the machine, the method further comprising analyzing at least some of the additional standardized feature vectors relative to the at least one standardized vector cluster to provide predictive maintenance information for the machine.

6. The method of claim 5, wherein analyzing at least some of the additional standardized feature vectors includes determining whether the additional standardized feature vectors analyzed fit within any of the at least one standardized vector cluster, thereby facilitating a determination as to whether a new operating mode cluster should be formed.

7. The method of claim 1, wherein the at least some of the feature vectors are standardized using vectors for a statistical mean for the collected data and vectors for a statistical standard deviation for the collected data, and

wherein transforming at least some of the standardized feature vectors into corresponding two-dimensional feature vectors includes extracting the first two principal components of each of the at least some standardized feature vectors to define a map from the standardized feature space to the two-dimensional feature space.

8. The method of claim 1, wherein analyzing at least some of the additional standardized feature vectors includes applying at least one of a classification-based system or a limit-based system.

9. The method of claim 8, wherein the classification-based system includes determining whether each of the additional two-dimensional feature vectors lies within any of the at least one two-dimensional vector clusters, and the limit-based system includes setting upper and lower limits and determining whether each of the additional two-dimensional feature vectors lies within the upper and lower limits.

10. The method of claim 9, wherein analyzing at least some of the additional standardized feature vectors includes applying the classification-based system, the limit-based system, and a velocity-based system, the velocity-based system including a determination of a corresponding velocity for each of the additional two-dimensional feature vectors and a comparison of each of the corresponding velocities to a predetermined velocity, and wherein application of each of the systems produces a corresponding diagnostic result which is assigned a weight value.

11. A method for predictive maintenance of a machine, the method comprising:

collecting feature data for the machine while the machine is operating, the feature data including a plurality of feature vectors;

standardizing at least some of the feature vectors to facilitate compatibility between the standardized feature vectors;

transforming at least some of the standardized feature vectors into corresponding two-dimensional feature vectors;

clustering at least some of the two-dimensional feature vectors based on the operating modes of the machine, thereby forming a plurality of two-dimensional operating mode clusters;

collecting additional feature data while the machine is operating, the additional feature data including a plurality of additional feature vectors;

standardizing at least some of the additional feature vectors;

transforming at least some of the additional standardized feature vectors into corresponding additional two-dimensional feature vectors; and

applying an algorithm to at least some of the additional two-dimensional feature vectors to facilitate a comparison between the operation of the machine when the feature data was collected and operation of the machine when the additional feature data was collected, thereby providing predictive maintenance information for the machine.

12. The method of claim 11, further comprising:

calculating a statistical mean for the feature data; and

calculating a statistical standard deviation for the feature data, thereby respectively creating vectors for the mean and standard deviation of the feature data, and

wherein standardizing at least some of the feature vectors includes applying the vectors for the mean and standard deviation of the feature data to the feature vectors to create the standardized feature vectors, and transforming at least some of the standardized feature vectors into corresponding two-dimensional feature vectors includes the use of a rotational transform which multiplies the at least some standardized feature vectors by a basis matrix, thereby computing principal components of the at least some standardized feature vectors.

13. The method of claim 11, wherein applying an algorithm to at least some of the additional standardized feature vectors includes applying at least one of a classification-based algorithm or a limit-based algorithm.

14. The method of claim 13, wherein the classification-based algorithm includes determining whether each of the additional two-dimensional feature vectors lies within any of the at least one two-dimensional vector clusters, and the limit-based algorithm includes setting upper and lower limits and determining whether each of the additional two-dimensional feature vectors lies within the upper and lower limits.

15. The method of claim 14, wherein applying an algorithm to at least some of the additional standardized feature vectors includes applying the classification-based algorithm, the limit-based algorithm, and a velocity-based algorithm, the velocity-based algorithm including a determination of a corresponding velocity for each of the additional two-dimensional feature vectors and a comparison each of the corresponding velocities to a predetermined velocity, and

wherein application of each of the systems produces a corresponding diagnostic result which is assigned a weight value.

16. The method of claim 11, wherein the clustering of at least some of the two-dimensional feature vectors includes forming a cluster based on an operating mode of the machine, and further includes forming, within the operating mode cluster, a cluster based on an operating condition of the machine, the operating condition occurring while the machine is operating in the operating mode.

17. The method of claim 16, wherein applying an algorithm to at least some of the additional two-dimensional feature vectors includes updating the operating condition cluster to determine a movement of the operating condition cluster toward a boundary of the operating mode cluster, thereby facilitating a determination of a future anomaly in the operation of the machine.

18. The method of claim 11, further comprising clustering at least some of the standardized feature vectors based on similarity between the standardized feature vectors, thereby forming at least one standardized vector cluster.

19. The method of claim 18, wherein the clustering of at least some of the standardized feature vectors includes forming a cluster based on an operating mode of the machine, the method further comprising analyzing at least some of the additional standardized feature vectors relative to the at least one standardized vector cluster to provide predictive maintenance information for the machine.

20. The method of claim 19, wherein analyzing at least some of the additional standardized feature vectors includes determining whether the additional standardized feature vectors analyzed fit within any of the at least one standardized vector cluster, thereby facilitating a determination as to whether a new operating mode cluster should be formed.

21. A method for predictive maintenance of a machine, the method comprising:

collecting feature data for the machine;

defining feature vectors from the feature data;

standardizing the feature vectors;

clustering the standardized feature vectors based on operating modes of the machine;

transforming the standardized feature vectors into corresponding two-dimensional feature vectors;

clustering the two-dimensional feature vectors at least based on the operating modes of the machine; and

recursively analyzing new feature data relative to at least some of the clusters, thereby providing predictive maintenance information for the machine.

22. The method of claim 21, wherein clustering the two-dimensional feature vectors includes a first clustering based on the operating modes of the machine, and a second clustering based on operating conditions of the machine, the operating conditions occurring within the operating modes.

23. The method of claim 21, wherein recursively analyzing new feature data includes using the new feature data to track movement of the operating condition clusters, thereby providing information related to a first type of machine anomaly.

24. The method of claim 21, wherein recursively analyzing new feature data includes using the new feature data to determine if new operating mode clusters should be formed, thereby providing information related to a second type of machine anomaly.

25. The method of claim 21, further comprising calculating standardized velocity for the standardized feature vectors, and wherein recursively analyzing new feature data includes applying at least one of:

a classification-based analysis, a limit-based analysis, or a velocity-based analysis.

26. The method of claim 25, wherein recursively analyzing new feature data includes applying the classification-based analysis, the limit-based analysis, and the velocity-based analysis, each of which produces a corresponding diagnostic result which is assigned a weight value.