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In industrial process monitoring, it is always a challenging and practical problem to analyze the causes of the system fault by isolating true fault variables from vast amounts of process data. However, the phenomenon of smearing effect occurs by using the traditional contribution analysis-based isolation methods since the defined isolation indices of different variables affect each other. In this paper, a new fault isolation method is proposed based on local outlier factor and improved k-nearest neighbor rule aiming to improve the isolation accuracy. Firstly, the nearest neighbors of each sample are obtained along the direction of a specific variable. Based on the nearest neighbors, the outlier-degree value of the variable is calculated and regarded as the contribution of the variable. Then, the contribution of the variable in all samples are obtained in the same way, among which the maximum one is selected as the isolation threshold value of this variable. During the online monitoring, the contribution of the variable in the newly collected sample is calculated in real time. Once the contribution is greater than the threshold, the variable is judged to be the dominant factor causing the system fault. Two cases on numerical example and Tennessee Eastman process are conducted to evaluate the effectiveness of the proposed method.

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In the present work, the design and the implementation of a Fault Detection and Isolation (FDI) system for an industrial machinery is proposed. The case study is represented by a multishaft centrifugal compressor used for the syngas manufacturing. The system has been conceived for the monitoring of the faults which may damage the multishaft centrifugal compressor: instrument single and multiple faults have been considered as well as process faults like fouling of the compressor stages and break of the thrust bearing. A new approach that combines Principal Component Analysis (PCA), Cluster Analysis and Pattern Recognition is developed. A novel procedure based on the statistical test ANOVA (ANalysis Of VAriance) is applied to determine the most suitable number of Principal Components (PCs). A key design issue of the proposed fault isolation scheme is the data Cluster Analysis performed to solve the practical issue of the complexity growth experienced when analyzing process faults, which typically involve many variables. In addition, an automatic online Pattern Recognition procedure for finding the most probable faults is proposed. Clustering procedure and Pattern Recognition are implemented within a Fuzzy Faults Classifier module. Experimental results on real plant data illustrate the validity of the approach. The main benefits produced by the FDI system concern the improvement of the maintenance operations, the enhancement of the reliability and availability of the compressor, the increase in the plant safety while achieving reduction in plant functioning costs.

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Fault detection and isolation is a ubiquitous task in current complex systems even in the linear networked case when the complexity is mainly caused by the complex network structure. A simple yet practically important special case of networked linear process systems is considered in this paper with only a single conserved extensive quantity but with a network structure containing loops. These loops make fault detection and isolation challenging to perform because the effect of fault is propagated back to where it first occurred. As a dynamic model of network elements, a two input single output (2ISO) LTI state-space model is proposed for fault detection and isolation where the fault enters as an additive linear term into the equations. No simultaneously occurring faults are considered. A steady state analysis and superposition principle are used to analyse the effect of faults in a subsystem that propagates to the sensors' measurements at different positions. This analysis is the basis of our fault detection and isolation procedure that provides the position of the faulty element in a given loop of the network. A disturbance observer is also proposed to estimate the magnitude of the fault inspired by a proportional-integral (PI) observer. The proposed fault isolation and fault estimation methods have been verified and validated by using two simulation case studies in the MATLAB/Simulink environment.

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This paper considers the active fault isolation problem for a class of uncertain multimode fault systems with a high-dimensional state-space model. It has been observed that the existing approaches in the literature based on a steady-state active fault isolation method are often accompanied by a large delay in making the correct isolation decision. To reduce such fault isolation latency significantly, this paper proposes a fast online active fault isolation method based on the construction of residual transient-state reachable set and transient-state separating hyperplane. The novelty and benefit of this strategy lies in the embedding of a new component called the set separation indicator, which is designed offline to distinguish the residual transient-state reachable sets of different system configurations at any given moment. Based on the results delivered by the set separation indicator, one can determine the specific moments at which the deterministic isolation is to be implemented during online diagnostics. Meanwhile, some alternative constant inputs can also be evaluated for isolation effects to determine better auxiliary excitation signals with smaller amplitudes and more differentiated separating hyperplanes. The validity of these results is verified by both a numerical comparison and an FPGA-in-loop experiment.

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This article deals with the cyber security of industrial control systems. Methods for detecting and isolating process faults and cyber-attacks, consisting of elementary actions named "cybernetic faults" that penetrate the control system and destructively affect its operation, are analysed. FDI fault detection and isolation methods and the assessment of control loop performance methods developed in the automation community are used to diagnose these anomalies. An integration of both approaches is proposed, which consists of checking the correct functioning of the control algorithm based on its model and tracking changes in the values of selected control loop performance indicators to supervise the control circuit. A binary diagnostic matrix was used to isolate anomalies. The presented approach requires only standard operating data (process variable (PV), setpoint (SP), and control signal (CV). The proposed concept was tested using the example of a control system for superheaters in a steam line of a power unit boiler. Cyber-attacks targeting other parts of the process were also included in the study to test the proposed approach's applicability, effectiveness, and limitations and identify further research directions.

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This paper deals with fault detection and isolation (FDI) in complex embedded wired communication networks. The considered faults are soft faults which do not prevent the communication, but may evolve into hard faults, i.e. short or open circuit. A novel FDI method based on power line communication (PLC) transmission systems is proposed. In these PLC systems, the transmission coefficients between the source and each receiver are estimated for communication purposes using orthogonal frequency division multiplexing (OFDM). Health indicators and residuals are computed by comparing the online estimated transmission coefficients with the reference coefficients. A methodology for dealing with complex networks, such as bus networks, is proposed. It is based on the decomposition of the network into several Y-shaped sub-networks. Each of these sub-networks is monitored to detect the presence of a fault. The FDI method is first validated using real data extracted from a Y-shaped network test bench. Then, the proposed approach is validated on a more complex network using realistic simulated data.

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Multiscale PCA (MSPCA) is a well-established fault-detection and isolation (FDI) technique. It utilizes wavelet analysis and PCA to extract important features from process data. This study demonstrates limitations in the conventional MSPCA fault detection algorithm, thereby proposing an enhanced MSPCA (EMSPCA) FDI algorithm that uses a new wavelet thresholding criterion. As such, it improves the projection of faults in the residual space and the threshold estimation of the fault detection statistic. When tested with a synthetic model, EMSPCA resulted in a 30% improvement in detection rate with equal false alarm rates. The EMSPCA algorithm also relies on the novel application of reconstruction-based fault isolation at multiple scales. The proposed algorithm reduces fault smearing and consequently improves fault isolation performance. The paper will further investigate the use of soft vs. hard wavelet thresholding, decimated vs. undecimated wavelet transforms, the choice of wavelet decomposition depth, and their implications on FDI performance.The FDI performance of the developed EMSPCA method was illustrated for sensor faults. This undertaking considered synthetic data, the simulated data of a continuously stirred reactor (CSTR), and experimental data from a packed-bed pilot plant. The results of these examples show the advantages of EMSPCA over existing techniques.

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With the development of Internet of Things (IoT) and edge computing technology, gas sensor arrays based on Micro-Electro-Mechanical System (MEMS) fabrication technique have broad application prospects in intelligent integrated systems, portable devices, and other fields. In such complex scenarios, the normal operation of a gas sensing system depends heavily on the accuracy of the sensor output. Therefore, a lightweight Self-Detection and Self-Calibration strategy for MEMS gas sensor arrays is proposed in this paper to monitor the working status of sensor arrays and correct the abnormal data in real time. Evaluations on real-world datasets indicate that the strategy has high performance of fault detection, isolation, and data recovery. Furthermore, our method has low computation complexity and low storage resource occupation. The board-level verification on CC1350 shows that the average calculation time and running power consumption of the algorithm are 0.28 ms and 9.884 mW. The proposed strategy can be deployed on most resource-limited IoT devices to improve the reliability of gas sensing systems.

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This paper investigates a design framework for a class of distributed interconnected systems, where a fault diagnosis scheme and a cooperative fault-tolerant control scheme are included. First of all, fault detection observers are designed for the interconnected subsystems, and the detection results will be spread to all subsystems in the form of a broadcast. Then, to locate the faulty subsystem accurately, fault isolation observers are further designed for the alarming subsystems in turn with the aid of an adaptive fault estimation technique. Based on this, the fault estimation information is used to compensate for the residuals, and then isolation decision logic is conducted. Moreover, the cooperative fault-tolerant control unit, where state feedback and cooperative compensation are both utilized, is introduced to ensure the stability of the whole system. Finally, the simulation of intelligent unmanned vehicle platooning is adopted to demonstrate the applicability and effectiveness of the proposed design framework.

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Linear dependence of variables is a commonly used assumption in most diagnostic systems for which many robust methodologies have been developed over the years. In case the system nonlinearities are relevant, fault diagnosis methods, relying on the assumption of linearity, might potentially provide unsatisfactory results in terms of false alarms and missed detections. In recent years, many authors have proposed machine learning (ML) techniques to improve fault diagnosis performance to mitigate this problem. Although very powerful, these techniques require faulty data samples that are representative of any fault scenario. Additionally, ML techniques suffer from issues related to overfitting and unpredictable performance in regions which are not fully explored in the training phase. This paper proposes a non-linear additive model to characterize the non-linear redundancy relationships among the system signals. Using the multivariate adaptive regression splines (MARS) algorithm, these relationships are identified directly from the data. Next, the non-linear redundancy relationships are linearized to derive a local time-dependent fault signature matrix. The faulty sensor can then be isolated by measuring the angular distance between the column vectors of the fault signature matrix and the primary residual vector. A quantitative analysis of fault isolation and fault estimation performance is performed by exploiting real data from multiple flights of a semi-autonomous aircraft, thus allowing a detailed quantitative comparison with state-of-the-art machine-learning-based fault diagnosis algorithms.

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A multiple-actuator fault isolation approach for overactuated electric vehicles (EVs) is designed with a minimal ℓ1-norm solution. As the numbers of driving motors and steering actuators increase beyond the number of controlled variables, an EV becomes an overactuated system, which exhibits actuator redundancy and enables the possibility of fault-tolerant control (FTC). On the other hand, an increase in the number of actuators also increases the possibility of simultaneously occurring multiple faults. To ensure EV reliability while driving, exact and fast fault isolation is required; however, the existing fault isolation methods demand high computational power or complicated procedures because the overactuated systems have many actuators, and the number of simultaneous fault occurrences is increased. The method proposed in this paper exploits the concept of sparsity. The underdetermined linear system is defined from the parity equation, and fault isolation is achieved by obtaining the sparsest nonzero component of the residuals from the minimal ℓ1-norm solution. Therefore, the locations of the faults can be obtained in a sequence, and only a consistently low computational load is required regardless of the isolated number of faults. The experimental results obtained with a scaled-down overactuated EV support the effectiveness of the proposed method, and a quantitative index of the sparsity condition for the target EV is discussed with a CarSim-connected MATLAB/Simulink simulation.

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This paper presents a novel directional observer-based fault detection and isolation scheme for second-order networked control systems (NCS). The directional unknown input observer (UIO) tool is exploited to study the problem of distributed fault detection and isolation (FDI). Two design schemes with global and partial/local network models are proposed to solve the distributed FDI problem. Thresholds are computed for the application of the proposed schemes in a noisy environment. In addition, the salient features of the proposed schemes are that both fault detection and fault isolation are achieved in a single step using a single observer. The schemes are applied to power system models to validate their results. A detailed comparison with existing FDI schemes is also provided, which clearly shows the effectiveness of the proposed scheme in terms of computational requirements.

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In networked control systems, sensor faults in a subsystem have a major influence on the entire network as the fault effect reaches the other subsystems through the network interconnections. In this paper, a fault diagnosis-oriented model is proposed for linear networked control systems that can be applied to the robotics platoon. In addition, this model can also be used to design distributed Unknown Input Observers (UIO) in each subsystem to accomplish weak sensor faults isolation by treating the network disturbances and fault propagation through the network as unknown inputs. A case study was developed in which the subsystems were represented by robots that are connected in a wireless communication-based leader-follower scheme. The simulation results show that the model successfully reproduces the expected behaviour of the robotics platoon in the presence of sensor faults. Furthermore, weak sensor faults isolation is also achieved by observing the residual signals produced by the UIOs in each of the subsystems.

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In order to solve the problem that the generalized likelihood test method cannot isolate the single fault of the four-gyro system and the double faults of the six-gyro system, a fault detection and isolation method combining the generalized likelihood test method with the residual error of the metabolism grey model is presented. The problem of isolating the single fault of the four-gyro system and the double faults of the six-gyro system using the generalized likelihood test method is analyzed. The method and process of fault detection and isolation are designed. The validity of the method presented in this paper is verified by simulation tests of the single fault of the four-gyro system and the double faults of the six-gyro system. By comparing the isolation performance with the generalized likelihood test method, it is proved that the isolation performance of the method proposed in this paper is better than that of the generalized likelihood test method. The method mentioned in this paper can effectively realize fault detection and isolation of the multi-gyro system and improve the inertial system's reliability.

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The primary focus of autonomous driving research is to improve driving accuracy and reliability. While great progress has been made, state-of-the-art algorithms still fail at times and some of these failures are due to the faults in sensors. Such failures may have fatal consequences. It therefore is important that automated cars foresee problems ahead as early as possible. By using real-world data and artificial injection of different types of sensor faults to the healthy signals, data models can be trained using machine learning techniques. This paper proposes a novel fault detection, isolation, identification and prediction (based on detection) architecture for multi-fault in multi-sensor systems, such as autonomous vehicles.Our detection, identification and isolation platform uses two distinct and efficient deep neural network architectures and obtained very impressive performance. Utilizing the sensor fault detection system's output, we then introduce our health index measure and use it to train the health index forecasting network.

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Recent catastrophic events in aviation have shown that current fault diagnosis schemes may not be enough to ensure a reliable and prompt sensor fault diagnosis. This paper describes a comparative analysis of consolidated data-driven sensor Fault Isolation (FI) and Fault Estimation (FE) techniques using flight data. Linear regression models, identified from data, are derived to build primary and transformed residuals. These residuals are then implemented to develop fault isolation schemes for 14 sensors of a semi-autonomous aircraft. Specifically, directional Mahalanobis distance-based and fault reconstruction-based techniques are compared in terms of their FI and FE performance. Then, a bank of Bayesian filters is proposed to compute, in flight, the fault belief for each sensor. Both the training and the validation of the schemes are performed using data from multiple flights. Artificial faults are injected into the fault-free sensor measurements to reproduce the occurrence of failures. A detailed evaluation of the techniques in terms of FI and FE performance is presented for failures on the air-data sensors, with special emphasis on the True Air Speed (TAS), Angle of Attack (AoA), and Angle of Sideslip (AoS) sensors.

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Ambient Assisted Living (AAL) is becoming crucial to help governments face the consequences of the emerging ageing population. It aims to motivate independent living of older adults at their place of residence by monitoring their activities in an unobtrusive way. However, challenges are still faced to develop a practical AAL system. One of those challenges is detecting failures in non-intrusive sensors in the presence of the non-deterministic human behaviour. This paper proposes sensor failure detection and isolation system in the AAL environments equipped with event-driven, ambient binary sensors. Association Rule mining is used to extract fault-free correlations between sensors during the nominal behaviour of the resident. Pruning is then applied to obtain a non-redundant set of rules that captures the strongest correlations between sensors. The pruned rules are then monitored in real-time to update the health status of each sensor according to the satisfaction and/or unsatisfaction of rules. A sensor is flagged as faulty when its health status falls below a certain threshold. The results show that detection and isolation of sensors using the proposed method could be achieved using unlabelled datasets and without prior knowledge of the sensors' topology.

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Subsea observation networks have gradually become the main means of deep-sea exploration. The reliability of the observation network is greatly affected by the severe undersea conditions. This study mainly focuses on theoretical research and the experimental platform verification of high-impedance and open-circuit fault detection for an underwater observation network. With the aid of deep learning, we perform the fault detection and prediction of the network operation. For the high-impedance and open-circuit fault detection of submarine cables, the entire system is modeled and simulated, and the voltage and current values of the operating nodes under different fault types are collected. Numerous calibrated data samples are supervised by a deep learning algorithm, and a fault location system model is built in the laboratory to verify the feasibility and superiority of the scheme. This paper also studies the fault isolation of the observation network, focusing on the communication protocol and the design of the fault isolation system. Experimental results verify the effectiveness of the proposed algorithm for the location and prediction of high-impedance and open-circuit faults, and the feasibility of the fault isolation system has also been verified. Moreover, the proposed methods greatly improve the reliability of undersea observation network systems.

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Perception sensors such as camera, radar, and lidar have gained considerable popularity in the automotive industry in recent years. In order to reach the next step towards automated driving it is necessary to implement fault diagnosis systems together with suitable mitigation solutions in automotive perception sensors. This is a crucial prerequisite, since the quality of an automated driving function strongly depends on the reliability of the perception data, especially under adverse conditions. This publication presents a systematic review on faults and suitable detection and recovery methods for automotive perception sensors and suggests a corresponding classification schema. A systematic literature analysis has been performed with focus on lidar in order to review the state-of-the-art and identify promising research opportunities. Faults related to adverse weather conditions have been studied the most, but often without providing suitable recovery methods. Issues related to sensor attachment and mechanical damage of the sensor cover were studied very little and provide opportunities for future research. Algorithms, which use the data stream of a single sensor, proofed to be a viable solution for both fault detection and recovery.

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Modern industrial processes and cyber-physical systems (CPS) are prone to anomalies both due to cyber and physical perturbations. Cyber disturbances or attacks being more hazardous may give birth to a series of multiple coordinated faults. In order to detect and isolate such faults, this paper proposes a novel distributed fault detection and isolation scheme for second-order networked systems. The system is assumed to be working in a cyber-physical environment where it is likely to face multiple simultaneous faults. Each node has access to measurements of states of its neighboring nodes. A distributed fault detection and isolation filter (DFDIF) is designed such that fault detection and fault isolation can be obtained in a single step. Using the proposed filter, each node can detect and isolate multiple simultaneous faults in its neighboring nodes. The detection and isolation of faults with a single filter at each node reduces the overall computational burden of distributed fault detection and isolation (DFDI) scheme. The proposed framework is tested for power network and robotic formations. Finally, a comparison with existing techniques is provided to prove the effectiveness of the proposed method.