Method of multi-level fault isolation design

• US 8,271,233 B2
• Filed: 04/01/2008
• Issued: 09/18/2012
• Est. Priority Date: 04/01/2008
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Butler, Steven W.
• Primary Examiner(s): Huynh, Phuong
• Application Number:
  US12/060,397
• Publication Number:
  US 20090248363A1
• Time in Patent Office: 1,631 Days
• Field of Search: 702185-190, 702/121
• US Class Current: 702/185
• CPC Class Codes: F01D 21/003 Arrangements for testing or measuring for measuring vibrations G01H
• CPC Class Codes: F01D 21/02 Shutting-down responsive to overspeed
• CPC Class Codes: F01D 21/12 responsive to temperature
• CPC Class Codes: F01D 21/14 responsive to other specific conditions
• CPC Class Codes: F01D 21/20 Checking operation of shut-down devices
• CPC Class Codes: F02K 3/06 with front fan

Abstract

A fault isolation method and system includes tailored fault isolators for each grouping of similar data to differentiate between one or several potential faults within any group.

Claims

1. A method of isolating a fault condition from many potential fault conditions comprising:

receiving a plurality of measured parameters indicative of a physical operating condition with a receiver;

generating a first group of potential faults with a controller receiving data from the receiver based on the plurality of input measured parameters by clustering individual potential faults together responsive to similarities in fault behavior within a defined range according to a defined acceptance criteria, wherein the defined acceptance criteria includes a capability of identifying a difference discernable by a fault isolator between at least two of the potential faults within the generated group meets;

selecting a first fault isolator with the controller from a plurality of fault isolators based on performance of the first fault isolator in differentiating between potential faults within the first group of potential faults;

applying the first isolator with the controller to the first group of potential faults to determine that at least one of the potential faults within the first group is not possible based on an evaluation conducted by the first fault isolator in differentiating between potential faults such that a second group that includes fewer potential faults than the first group of potential faults is generated based on an evaluation of each of the potential faults within the first group conducted by the first fault isolator; and

communicating a fault condition with a communication device responsive to the redefined group of potential faults including one potential fault.

2. The method as recited in claim 1, including the step of selecting a second isolator different than the first isolator from the plurality of isolators with the controller responsive to the redefined group including more than one potential fault, wherein the second isolator is selected based on performance of the second isolator in differentiating between potential faults in the redefined group of potential faults.

3. The method as recited in claim 1, wherein the group of potential faults is generated by clustering individual potential faults together responsive to similarities in fault behavior within a defined range.

4. The method as recited in claim 3, wherein similarities in fault behavior are quantified by measuring differences between fault classes within a confusion matrix.

8. The method as recited in claim 1, including the step of performing a maintenance operation on a mechanical system corresponding with the reported fault condition.

5. A method of isolating a fault condition from many potential fault conditions comprising:

receiving a plurality of measured parameters indicative of a physical operating condition with receiver;

generating a first group of potential faults with a controller based on the plurality of input measured parameters from the receiver, wherein the group of potential faults is generated by clustering individual potential faults together responsive to similarities in fault behavior within a defined range;

selecting a first isolator within the controller from a plurality of isolators based on performance of the first isolator in differentiating between fault behavior within the defined range of faults within the first group of potential faults;

applying the first isolator to the group of potential faults to eliminate at least one of the potential faults within the first group based on differentiating between fault behavior by the first isolator such that a second group is generated that includes fewer potential faults than a previous first group of potential faults based on evaluations of each of the potential faults conducted by the first isolator; and

communicating a fault condition with a communication device responsive to the redefined group of potential faults including one potential fault, wherein the group of potential faults is accepted responsive to a difference discernable by the first isolator between at least two potential faults being within a desired acceptance criteria.

6. The method as recited in claim 5, wherein the acceptance criteria comprises a desired frequency of obtaining a correctly identified fault condition.

7. The method as recited in claim 5, wherein the acceptance criteria comprises a desired frequency of obtaining a correctly consolidated group.

9. A fault isolator for determining a fault condition of a system comprising:

a receiver for receiving parameter data indicative of system performance;

a controller receiving data from the receiver, the controller including,

a first isolator for differentiating between at least two potential faults from a group of potential faults indicated by the received data;

a second fault isolator different than the first isolator for differentiating between potential faults not discernable by the first isolator, wherein the first isolator and the second fault isolator are selected responsive to a determined ability to discern between at least two potential faults within a group of potential faults; and

a communication device for communicating the fault condition determined by criteria of the first and second isolators.

10. The fault isolator as recited in claim 9, wherein the first isolator comprises a model of the system utilized for discerning between at least two of the potential faults from the group of potential faults.

11. The fault isolator as recite in claim 10, wherein the second isolator comprises a model of the system different than the model of the system utilized for the first isolator.

12. A fault isolator for determining a fault condition of a system comprising:

a receiver for receiving parameter data indicative of system performance;

a controller receiving data from the receiver, the controller including,

a first isolator for differentiating between at least two potential faults from a group of potential faults indicated by the received data;

a second fault isolator different than the first isolator for differentiating between potential faults not discernable by the first isolator; and

a communication device for communicating the fault condition determined by eliminating potential fault conditions by differentiating between a group of potential faults with the first and second isolators, wherein each of the first fault isolator and the second fault isolator are selected based on a previously tested capability of differentiating between potential fault conditions within a sample set of data indicative of system performance and indicative of known fault conditions.