Model-based fault detection and isolation system and method

• US 6,766,230 B1
• Filed: 11/09/2001
• Issued: 07/20/2004
• Est. Priority Date: 11/09/2000
• Status: Expired due to Term

• Current Assignee: Delphi Automotive Systems LLC (BorgWarner Incorporated), Steering Solutions IP Holding Corporation (Nexteer Automotive Group Ltd.), Ohio State University
• Original Assignee: Delphi Automotive Systems LLC (BorgWarner Incorporated), Ohio State University
• Inventors: Rizzoni, Giorgio, Murray, Brian T., Amberkar, Sanket S., Soliman, Ahmed, Pisu, Pierluigi
• Primary Examiner(s): Zanelli, Michael J.
• Application Number:
  US10/039,634
• Time in Patent Office: 984 Days
• Field of Search: 701/29, 701/33
• US Class Current: 701/29
• CPC Class Codes: B60G 17/0185 for failure detection
• CPC Class Codes: B60G 2600/042 Monitoring means
• CPC Class Codes: B60G 2600/08 Failure or malfunction detecting means
• CPC Class Codes: B60G 2600/1873 Model Following
• CPC Class Codes: B60G 2800/80 Detection or control after a system or component failure
• CPC Class Codes: B60G 2800/85 System Prioritisation
• CPC Class Codes: B60W 2050/0028 Mathematical models, e.g. for simulation
• CPC Class Codes: B60W 2050/0295 Inhibiting action of specific actuators or systems
• CPC Class Codes: B60W 50/00 Details of control systems for road vehicle drive control not related to the control of a particular sub-unit , e.g. process diagnostic or vehicle driver interfaces
• CPC Class Codes: B60W 50/0205 Diagnosing or detecting failures; Failure detection models
• CPC Class Codes: G05B 23/0251 Abstraction hierarchy, e.g. "complex systems", i.e. system is divided in subsystems, subsystems are monitored and results are combined to decide on status of whole system
• CPC Class Codes: G05B 23/0278 Qualitative, e.g. if-then rules; Fuzzy logic; Lookup tables; Symptomatic search; FMEA

Abstract

A model-based Fault Detection and Isolation (FDI) system and method based on a hierarchical structure for monitoring overall vehicle system performance and diagnosing faults is disclosed. The FDI scheme uses the available sensors in a vehicle system and divides them into subsystems of smaller dimensions containing one or more modules that are related or interconnected. The same module may appear in a different subsystem, but the set of all subsystems does not have to contain all of the modules. For this structure, an FDI scheme comprising several detector units is created. Each detector unit receives information from the sensors and outputs a residual that is sent to a residual evaluation unit which processes the data and performs the residual evaluation for the selected subsystem. Finally, each subsystem outputs a decision that is sent to a supervisor unit performing the final diagnosis.

Claims

1. A method for fault diagnosis in a transport device comprising the steps of:

partitioning a transport device model into a plurality of subsystems, each subsystem comprising one or more modules;

associating a fault detector unit with each module in each subsystem;

defining a residual evaluation method for each subsystem;

evaluating data from said fault detector units in accordance with said residual evaluation method for each subsystem; and

diagnosing a fault in accordance with said evaluated data.

2. The method of claim 1 wherein the step of defining a residual evaluation method for each subsystem comprises the step of defining a residual evaluation method selected from the group consisting of parity space method, observer method, and parameter identification method.

3. The method of claim 1 wherein the step of partitioning a transport device model into a plurality of subsystems comprises the step of partitioning said transport device model into a core subsystem and an external subsystem.

4. The method of claim 3 wherein the core subsystem comprises a transport device dynamics module, a tire module, a powertrain module, a steering module, a suspension module, and a brake module.

5. The method of claim 3 wherein the external subsystem comprises an environmental module, a driver module, a sensor module, a brake controller module, a suspension controller module, and a communication module.

6. The method of claim 3 wherein said subsystem modules are selected from the group of modules consisting of vehicle, tire, powertrain, steering, suspension, brake, environmental, driver, sensor, brake controller, suspension controller, communication, engine controller, fuel, air intake, combustion, exhaust, crank-shaft, transmission, coupling, supervisory controller, electric machine, controller, batteries/supercapacitors, tank, pump, servo-valve, and cylinder modules.

7. The method of claim 3 wherein said plurality of subsystems comprises a handling system, a propulsion system, and an auxiliary system.

8. A system for problem diagnosis in a transport device comprising:

a plurality of residual evaluation units;

a plurality of fault detector units in communication with said plurality of residual evaluation units, each of said plurality of fault detector units adapted to communicate fault data to at least one of said-residual evaluation units; and

a supervisor unit adapted to analyze evaluated data from plurality of residual evaluation units and to diagnose a problem in accordance with said data from said plurality of residual evaluation units.

9. The system of claim 8 wherein each of said residual evaluation units evaluates fault data in accordance with a residual evaluation method selected from the group of evaluation methods consisting of parity space method, observer method, and parameter identification method.

10. The system of claim 8 wherein said plurality of residual evaluation units comprises a brake/suspension/steering residual evaluation unit, a tire/vehicle dynamic residual evaluation unit, and a powertrain/driver residual evaluation unit.

11. The system of claim 8 wherein each of said plurality of fault detector units comprises a primary residual generator adapted to generate fault data.

12. The system of claim 11 wherein said primary residual generator is adapted to generate a primary residual representing the error between a measured and calculated variable.

13. The system of claim 8 wherein each of said residual evaluation units comprises a secondary residual generator, a residual evaluator, and a decision unit.

14. The system of claim 8 wherein each of said plurality of fault detector units comprises a model associated with a module.

15. The system of claim 14 wherein said module is selected from the group consisting of transport device, tire, powertrain, steering, suspension, brake, environmental, driver, sensor, brake controller, suspension controller, communication, engine controller, fuel, air intake, combustion, exhaust, crank-shaft, transmission, coupling, supervisory controller, electric machine, controller, batteries/supercapacitors, tank, pump, servo-valve, and cylinder modules.

16. A transport device comprising:

a first plurality of fault detector units associated with a first module in said transport device adapted to output residuals for said first module;

a second plurality of fault detector units associated with a second module in said transport device adapted to output residuals for said second module;

a first residual evaluation unit adapted to receive and process in accordance with a first residual evaluation method said residuals from said first plurality of fault detector units;

a second residual evaluation unit adapted to receive and process in accordance with a second residual evaluation method said residuals from said second plurality of fault detector units; and

a supervisor unit adapted to receive output from said first residual evaluation unit and said second residual evaluation unit and to diagnose a fault in accordance with said output from said first residual evaluation unit and said second residual evaluation unit.

17. The transport device of claim 16 wherein each of said fault detector units comprises a model and a primary residual generator adapted to generate a residual in accordance with output from said model.

18. The transport device of claim 16 wherein said first module is associated with a core subsystem.

19. The transport device of claim 16 wherein said second module is associated with an external subsystem.

20. The transport device of claim 16 wherein said first module and said second module are selected from the group of modules consisting of sensor, brake controller, suspension controller, communication, brake, driver, steering, transport device, suspension, powertrain, tire, environmental, engine controller, fuel, air intake, combustion, exhaust, crank-shaft, transmission, coupling, supervisory controller, electric machine, controller, batteries/supercapacitors, tank, pump, servo-valve, and cylinder modules.

21. The transport device of claim 16 wherein each of said residual evaluation units comprises a secondary residual generator a residual evaluator, and a decision unit.

22. The transport device of claim 16 wherein said first residual evaluation method and said second residual evaluation method are selected from the group of evaluation methods consisting of parity space method, observer method, and parameter identification method.

23. The transport device of claim 16 wherein said first module is in a handling system.

24. The transport device of claim 16 wherein said first module is in a propulsion system.

25. The transport device of claim 16 wherein said first module is in an auxiliary system.