IMECE2008-67260: Model Based System Monitor Using Artificial Neural Networks (Ann)
IMECE2008-67260: Model Based System Monitor Using Artificial Neural Networks (Ann)
IMECE2008-67260: Model Based System Monitor Using Artificial Neural Networks (Ann)
Congress and
of Exposition
IMECE2008
IMECE2008
2008 ASME International Mechanical Engineering Congress and Exposition
October 31 –November 6, 2008, Boston, Massachusetts, USA
October 31-November 6, 2008, Boston, Massachusetts, USA
IMECE2008-67260
ABSTRACT One of the most frequently used way for fault detection in
Nowadays, with the integration of diverse mechatronic this case is threshold checking. This method supports the
components, a mechatronic system is capable of performing system with basic functional safety, and requires little
more difficult and complex tasks. At the same time, it calculation effort. The targets of the threshold checking are
becomes more and more difficult to develop a system to measureable system parameters, like force F, torque T,
ensure the safety of these complex mechatronic systems. rotational speed n, temperature T, pressure P, etc. The state of
the system is monitored with the method. Furthermore, in an
This paper outlines a novel method for fault detection, automation system it is necessary to ensure the functionality of
which uses a neural network monitor based on a feed forward the mechatronic components. By means of timing constraint a
back propagation (FFBP) algorithm. The goal of this study is monitor can determine, whether a required action is
to develop a real-time capable method for detection of accomplished within a defined time interval. In order to have
abnormal or faulty behavior of an automation system. An an overview of fault-detection methods, a summarization of
example is used to illuminate the capability of the neural the practical fault-detection methods is shown in Figure 1.
network in modeling and real-time data in this work.
Furthermore this method is validated on a test bed, which is FAULT‐DETECTION METHODS
developed at the institute of product development Karlsruhe
(IPEK). This method will allow the monitor to detect critical detection with detection with multiple
single signals signals and models
state of the system due to unexpected influences in real-time,
so that safety hazard to personnel and equipment caused by limit trend signal process multi‐variant
checking checking models used models used data analysis
the fault can be prevented or mitigated.
parameter neural principal
Keywords: ANN, model based system monitor, reliability fixed
threshold
adaptive
thresholds
correl‐
ation
spectrum
analysis estimation networks component
analysis
engineering, change state limit
wavelet
detection observers checking
analysis
methods
INTRODUCTION parity
equations
Due to the development of automation systems,
tremendous progress has been achieved in manufacture,
transportation and energy systems. With the increasing Figure 1. Survey on fault-detection methods [1]
integration of mechatronic components in technical systems,
the correct behaviors of all actuators, sensors and control units The methods for fault detection can be divided into the
are more and more critical to the environment, business and following parts:
the safety of operators and equipments. Hence, the • fault detection with single signals
functionality and the reliability of the automation system - through limit checking
should be assured during the operation process. - through trend checking
1
Professor and author of correspondence, Phone: +49 (721) 608 2371, Email: [email protected]
Figure 2. Concept of model based system monitoring [2] The FA, FR and FG can be calculated with equations (3) [5]:
v2
In practical application it is required that the monitor is FA = cw ⋅ A ⋅ ρ ⋅
capable of online data processing. The development of a real- 2 (3)
time capable system model for the model based monitor FR = f R ⋅ m ⋅ g
becomes a focus of this study. This work presents feed FG = m ⋅ g ⋅ sin α
forward back propagation Network (FFBP) to build the
system. The object of the monitor in this study is a limousine Where the cW, A, ρ, fR, g and α denote drag coefficient,
with front-engine rear-wheel-drive, 2.5 liter 6 cylinder cross-sectional area, atmospheric density, rolling resistance
gasoline engine, 5-speed manual transmission and friction coefficient, acceleration due to gravity and road gradient.
clutch. The goal of the actual work is to monitor the vehicle’s The tire tractive (braking) force Ft in equation (1) is the
start up process. Simple descriptions of vehicle dynamic and force on the contact patch of tires. It is the average friction
test process are introduced in section 2. Section 3 describes the force of the driving wheels for acceleration and the average
method of monitoring vehicle longitudinal dynamic and the friction force of all wheels for deceleration.
ANN based vehicle model. The validation of the model is
described in Section 4, followed by conclusions. Considering the functions of the clutch, brake and
transmission systems in the drive train, it is difficult to
VEHICLE MODEL AND TEST PROCEDURE describe the vehicle dynamic with simple equations. An
Vehicle Longitudinal Dynamics Model alternative method to describe vehicle longitudinal dynamic is
The integration of diverse mechatronic components in the to use computer aided simulation technique. Figure 4 shows
vehicle has enhanced the driving safety and ride comfort. the demonstration of a model structure for simulation of
Concerning the complexity of the mechatronic components in vehicle longitudinal dynamic. The difficulties by modeling a
the vehicle, a monitor system is necessary to ensure the vehicle system with non-linear physical based models are:
functionally and reliability of these components. Methods for • it needs great effort to determine parameters in the
monitoring or checking software and hardware performance vehicle model, and
[3], [4] can hardly meet the increasing reliability requirements
ai = g (∑ j =0 W j ,i a j )
On the other hand, because of the complexity of the n
model, the vehicle model requires great calculation effort. It Bias Weight
can be difficult to satisfy the real-time requirement of an on- a0= -1 W0,i
g
line monitoring system. ini
-C-
Clutch
Input Input Activation Output Output
Pedal n_Gearbox_in
Links Function Function Links
-C- Acc Pedal Clutch Pedal T_Clutch
Accelerator n_Engine n_DMF_prim.
Pedal T_clutch
DMF & Clutch
Figure 5. A simple mathematical model for a neuron.
Engine
The unit’s output is ai, and aj is the output activation of
unit j and Wj,i is the weight on the link from unit j to this
-C- N_of_ratio n_Gearbox_in unit [8]
Number of
Ratio steps T_Clutch n_Gearbox_out Test procedure
Gearbox The development of an ANN based vehicle model follows
the process of VDI 2206 [9], which is shown in Figure 6.
requirements product
n_G_out n_Drivetrain
Drive train
v_vehicle
F_Drive
v_vehicle
-C- Slope
Slope
Vehicle Mass
domain‐specific design
Front-engine real -wheel -drive , gasoline engine, mechanical engineering
manual transmission and friction clutch, electronical engineering
information technology
Figure 4. Demonstration of simplified vehicle model
The investigation shows that the vehicle velocity is a Figure 6. V-model as macro cycle [9]
function of accelerator pedal travel PA, brake pedal travel PB,
clutch pedal travel PC, engine speed nEngine, road gradient α, With the analysis of the vehicle system, as shown in
number of ratio steps i, etc. section 2.1, it is possible:
v = f ( PA , PB , PC , n Engine ,α , i,...) (4) • to obtain an overview of the system,
The preliminary studies [6] [7], show that among the • to determine parameters which are relevant to the
methods for modeling the vehicle longitudinal dynamics, network,
ANN based models are more efficient compared to other
models, such as non-linear physical based models or • to determine characteristics of the parameters. For
mathematical approximate models. instance, a state parameter like number of ratio steps i,
describes actual selected gear ratio, and parameter like
ANN is a mathematical model, which is based on brake pedal travel PB, influences the system
biological neural network. It is composed of nodes, or units progressively. The influence can be described as
connected by links, as shown in Figure 5. A link from unit j to integration of PB.
unit i serves to propagate the activation aj from j to i. Each
nEngine PA PB PC Rate
[rpm] [%] [%] [%] [-]
1600 - 0 - 0
Inputs Layer 1 Layer 2
1600 - 25 slow 0
T
D IW1,1 n1(t) LW2,1 n2 (t)
L S1 x 1 S2 x 1
S1 x f1 S 2 x S1 f2
d (R1d)
… … … … … R1
1
S1 x
b1
1
S1 x 1
S1
1 b2
S2 x 1
S2 x 1
S2
0.08
Error in Validation
Error
monitor
… … … … … 0.06
0.04
4000 - 25 0 slow
0.02
Error [-]
-0.02
… … … … … -0.04
-0.06
-0.1
284 285 286 287 288 289
t [s]
290 291 292 293 294
The real-time inputs u(t) chosen for this work are the
accelerator pedal travel PA_RT, brake pedal travel PB_RT, clutch (a)
pedal travel PC_RT and engine speed nEnginer_RT, etc. The input
parameters with defined delay time are the travel of three
pedals, PA_TD, PB_TD, PC_TD, and mean value of the wheel
speeds nWheel_TD, etc. Regarding reaction time of a normal
driver and response time of a vehicle system, the delay time is
set to 0.1 second. In order to improve the simulation quality of
the networks, further methods for the data manipulation are
considered in this work.
nTarget n
0.4 Clutch Target Accelerator Pedal
0.3 n nEngine
Sim
nO,GearboxD
0.2
nSim Accelerator
0.28 Pedal
0
Y [-]
0.26 -0.2
nEngine
Brake -0.4 n
Engine
0.24
-0.6
(b) -1
317 318 319 320 321 322 323 324 325 326
Training result - error t [s]
0.1
0.08
(a)
Validation results - Brake drift error
0.06 0.1
Error
0.04
0.08
0.02
0.06
Error [-]
0
0.04
-0.02
0.02
-0.04
Y [-]
0
-0.06
-0.02
-0.08
-0.04
-0.1
0 100 200 300 400 500 600
t [s]
-0.06
(c) -0.08
Sim
0.6 Target
Validation of the ANN model Clutch
The validation of the model proceeds under regarding of 0.4
Brake
Accelerator Pedal
Clutch
the following points: nEngine
0.2 nO,GearboxD
• ability of the model to detect fault by defect sensor Accelerator
(drift, total defect) 0 Pedal
Y [-]
system components
-0.4
n
•
Engine
real time capability of the model Brake
-0.6
that there is drift effect on the sensor for measure of the brake
pedal travel. In this case measured value has drift effect in the (c)
time interval between 317.0s and 328.8s. Figure 12 illustrates
the behavior of the model when receiving input signal afflicted
0
0.000141 second. Because of the limitation of data transport
-0.02
technique using UDP/IP, the transport of input data through
-0.04 TCP/IP connection at a frequency of 100 Hz or higher is not
real-time capable. Thus the processing of data with the length
-0.06
of 20 seconds needs in this experiment 33.6480 seconds.
-0.08
-C- K*u K*u
-0.1 Network Inputs IW{1,1} netsum tansig LW{2,1}
317 318 319 320 321 322 323 324 325 326
t [s] -C-
Layer 1
b{1}
(d)
Figure 12. Validation of the vehicle model with abnormal
inputs signals -C- K*u
(a) Diagram of validation results with abnormal brake b{2}
netsum1 tansig1 LW{3,2} Layer 2
signal as input. (b) Absolute error of the simulation result
shown in (a). (c) Diagram of validation results with
original brake signal as input. (d) Absolute error of the
simulation result shown in (c) -C- *K
netsum2 tansig2 Matrix Layer 3
b{3}
reshape
The validation of the model in case of partly defect
system component is similar to the first test. Both of the
experiments use model-in-the-Loop (MiL) technique to verify Target Scope
Id: 1
the functional capability of the model. Scope (xPC)
(a) (b)
Figure 15. Validation of the vehicle model on SIRIUS-
Box
Figure 13. Sirius Box Further experiments are performed on a universal drive
train test bench which is developed in the IPEK(Figure 16).
By using rapid-prototyping software xPC-TargetTM from Goal of these experiments is to validate the monitor on a
the Mathworks, the box can validate the vehicle model in real- general real system.
time. Hence the influences on the validation test deriving from
the operating system and software can be ignored.
REFERENCES
[1] Isermann, R., 2006, Fault-Diagnosis Systems, Springer-
Verlag, Berlin Heidelberg New York.
[2] Isermann, R., 1994, Überwachung und Fehlerdiagnose:
Moderne Methode und ihre Anwendung bei technischen
Figure 16. Universal drive train test bench with drive Systemen, VDI-Verlag, Düsseldorf.
train of upper middle class vehicle and electric clutch [3] Burkhart, H. and Millen, R., 1999, “Performance-
actuation device measurement tools in a multiprocessor environment”,
IEEE transaction on computers, Vol. 38, No. 5.
CONCLUSIONS AND FUTURE WORKS [4] Ray, F., 1990, “Monitoring distributed embedded
This work it proves that the model based monitor using systems”, Proceedings of the 1990 Symposium on
ANN is one of the promising methods to supervise the Applied Computing.
mechatronic systems [6] [7]. The FFBP network introduced in [5] Grote, K.-H. and Feldhusen, J., 2005, “Dubbel -
this work is validated regarding the real-time capability and Taschenbuch für den Maschinenbau”, Springer-Verlag
the simulation accuracy. This monitoring technique can be
applied on complex nonlinear mechatronic systems, in which [6] Albers, A.; Ott, S.; Wang, J., 2007, “Attempt of
the requirements of an online model based monitor can be Prediction of Vehicle Longitudinal Dynamic
difficult satisfied by physical based system models or Performance using Artificial Neural Networks (ANN) ”,
mathematical approximate models. ASME IDETC: 9th International Conference on
Advanced Vehicle and Tire Technologies (AVTT), 04.-07.
Further works will concentrate in September 2007, Las Vegas, Nevada, USA.
• standardization of the processes by building ANN [7] Albers, A.; Wang, J.; Ott, S.; Düser, T.; Lerspalungsanti,
model and S., 2008, “Application of Artificial Neural Networks
• design of real-time fault diagnosis technique using (ANN) Based Model for Monitoring of Vehicle
online FMEA. Longitudinal Dynamic Performance”, ASME IDETC:
10th International Conference on Advanced Vehicle and
ACKNOWLEDGMENTS Tire Technologies (AVTT), August 3-6, 2008, Brooklyn,
This paper is part supported by project of “model based New York, USA.
monitor for measuring equipments and test benches” under the [8] Russell, S.; Norvig, P., 2003, Artificial Intelligence: A
grant of PRO INNO II1 KF0398803MB7. Modern Approach 2/E, Prentice Hall
[9] VDI 2206, 2004, Design methodology for mechatronic
systems, Verein Deutscher Ingenieure, Düsseldorf
APPENDIX NOMENCLATURE
α road gradient [10] Kleppmann, W., 2001, Taschenbuch Versuchsplanung,
A vehicle cross-sectional area Carl Hanser Verlag, München, Wien.
cW drag coefficient [11] Klein, B., 2004, Versuchsplannung – DoE, Oldenbourg
FA air resistance Wissenschaftsverlag GmbH.
FG gradient resistance [12] Huang, G.-B., Zhu, Q.-Y. and Siew C.-K., 2006, “Real-
fR rolling resistance coefficient Time Learning Capability of Neural Networks”, IEEE
FR rolling resistance Transactions on Neural Networks. Vol. 17, No. 4, pp.
Ft tire tractive (braking) force 863 – 878
FTR tractive resistance
g acceleration due to gravity [13] Demuth, H., Beale, M. and Hagan, M., 2006, “Neural
i number of ratio steps Network Toolbox User’s Guide”, The MathWorks
ρ atmospheric density
PA accelerator pedal travel
PB brake pedal travel
PC clutch pedal travel
nEngine engine speed
1
PROgramm „Förderung der Erhöhung der INNOvationskompetenz
mittelständischer Unternehmen“ (PRO INNO II) des Bundesministeriums für
Wirtschaft und Technologie (BMWi)