Expert System Design For Fault Diagnosis in Diesel Engines
Expert System Design For Fault Diagnosis in Diesel Engines
Expert System Design For Fault Diagnosis in Diesel Engines
emphasize ES, especially one that develops a database with one of great importance is the diesel engine. So having a tool
symptoms and possible causes that presents the equipment, so that facilitates and accelerates the detection and diagnosis of
that the user selects the symptoms and the ES determines the their condition greatly helps in the optimal maintenance and
cause. Additionally, Sisteplant [9] presents the PRISMA 3 therefore in the proper functioning of the processes in which it
GMAO platform of general application, composed of several is involved. This is why a Diagnosis ES for Hyundai Diesel
modules where it highlights the Knowledge Management, Engines CRDi 2.0 integrated with CBM techniques is
where it has an ES of fault diagnosis with decision rules. developed.
Similarly, Invensys Systems [10] develops the Avantis
A. Organization of the information of diagnosis expert
Condition Manager program, which is an intelligent real-time
system
condition management program of general application that
collects and analyzes real-time diagnostics from all plan The Diagnosis ES for Hyundai Diesel Engines CRDi 2.0 is
production assets. This program integrates different techniques developed with information from two experts in the field and
such as CBM, Multi-Variable ES with rules-based engine, information that is entered from the analysis performed on the
Enterprise Asset Management (EAM)/CMMS, Enterprise engine, which are related to the application of CBM
Resource Planning (ERP) and Business Intelligence systems. techniques, for the respective diagnosis. This information is
More recently, Villa et al [11] propose a SCADA ES to model internally organized around three main structural components:
failure modes of a ropeway for massive transportation, where Knowledge Base, Database of Facts and Inference Engine. Fig.
sensors are used to measure real-time information that feeds 1 shows the main components and other components that form
the Fuzzy ES that is combined with CBM techniques to the internal structure of the ES developed.
facilitate the operation, maintenance and safety of the cable
car. In addition, Akinluli et al [12] developed a Fault
Diagnosis ES for excavators, which has a simple structure that
can diagnose faults occurring in these machines taking into
account their different symptoms, so that this system
contributes in repair and maintenance of these excavators.
Furthermore, Galar et al [13] propose a hybrid model-based
maintenance decision system, which uses a data-driven model
to find and confirm the physical damage of an asset, taking
into account historical data from CM measurements with
Fuzzy ES and work orders taken from a CMMS that manages
the maintenance of these assets. The operating conditions in
this model are related to the accumulation of degradation in a
system with consideration of aspects driven by context.
Considering that faults diagnosis in diesel engines is a critical
part in maintaining them and that there are no tools that
facilitate the diagnosis, in this work is developed a Diagnosis
ES for Hyundai Diesel Engines CRDi 2.0, which in
combination with CBM techniques it joins a CMMS for diesel
engines in the automotive area.
recommendations, so that the user selects Cause 2 and the ES Failure Modes, Possible Causes, Recommendations or
gives the Recommendation 2. Corrective Actions, and Recommended CBM Techniques.
Then there is the section of Possible Causes, where they D. Interface of the diagnosis expert system
have different causes related to each failure that occurs in the The Interface of Diagnosis ES is developed in HTML
engine, which are extracted from the knowledge of experts in 5 code, and is composed of five sections that are Homepage,
the field. For each cause presented, it has a number of Diesel Engine, Diesel Engine Structure, Condition Detection,
maintenance actions recommended by experts in the and Troubleshooting. Below are some views of the Diagnosis
Recommendations or Corrective Actions section. In addition, ES developed, where can be observed each section in the
for each cause also they have recommendations for CBM interface of the ES [17].
techniques that should be used to detect the cause of the In Fig. 5, the Homepage section with a brief description of
failure, which are within the Recommended CBM Techniques the Diagnosis ES for Hyundai Diesel Engines CRDi 2.0 can be
section, where it says which of the CBM analysis should be observed. In this section, the user can find an introduction to
performed for optimal data. the program with an explanation of what to find in each part of
Fig. 4 shows the complete architecture of the Diagnosis ES the Diagnosis ES.
for Hyundai Diesel Engine CRDi 2.0 described.
list of links that shows each possible cause of this failure. Fig. III. DIAGNOSIS EXPERT SYSTEM INTEGRATED TO A CMMS
11 presents an example of one of the possible causes of the FOR DIESEL ENGINES
failure, where the user can find recommendations and The Diagnosis ES developed for Hyundai Diesel Engines
corrective actions. As shown in Fig. 11, the Diagnosis ES CRDi 2.0 is integrated within a module of a CMMS for
presents in this section the procedures, personnel and materials maintenance of diesel engines in the automotive area
needed to perform the maintenance activities. At the end of represented in Fig.12. This ES together with CBM analyzes
this part of Troubleshooting section, the ES presents performed to the engine are recorded in the Detection and
Recommended CBM Techniques for each cause of each Diagnosis Management Module, which interacts with other
failure of the Hyundai Diesel Engine CRDi 2.0. modules related to the maintenance management of diesel
engines, and which is structured as shown in Fig. 13.
Fig. 11. Example of a Possible Cause in the Troubleshooting section Fig. 13. Scheme of the Detection and Diagnosis Management
of the Diagnosis ES. Module of the CMMS for Diesel Engines.
Considering the above, Figure 15 shows a process flow Fig. 15. Diagram of process of interaction between Diagnosis ES, the
diagram describing the integrated behavior between Diagnosis CBM and CMMS for Diesel Engines.
ES, CBM and CMMS for diesel engines. In this diagram is
considered as an initial step the creation of a predictive
maintenance work order in the CMMS, whether the IV. ANALYSIS
maintenance activity has been scheduled or maintenance The developed system is simple to use because it provides
personnel has requested the activity because the engine has a the user with important information about Hyundai Diesel
possible fault or any irregular situation. Engine CRDi 2.0 through a friendly interface, so that at a
critical moment of the engine, the system can help solve the [10] Invensys Systems Inc. [online], Avantis Condition Manager (2014),
http://software.schneider-electric.com/pdf/datasheet/avantis-condition-
problem quickly and effectively.
manager/. Access: October 17, 2015.
In addition, this Diagnosis ES has the originality to come [11] L., Villa, O. Quintero, L. Castañeda, G. Mejíac, Fuzzy Inference System
structured so that it can be easily integrated into a CMMS for for Modelling Failure Modes in a Ropeway for Massive
diesel engines that take into account the CBM techniques for Transportation, 2015 International Conference on Artificial Intelligence
the detection and diagnosis of engine failures. This ES through and Industrial Engineering (AIIE 2015), Phuket, Thailand, 2015, pp.
113-116.
a CMMS helps decision making in terms of maintenance [12] O. Akinluli, V. Bagolun, T. Azeez, Development of an Expert System
activities for this engine according to the different alert levels for the Repair and Maintenance of Bulldozer’s Work Equipment
that can present considering the behavior of the engine Failure, ISSN: 2229-5518, International Journal of Scientific &
variables measured by CBM techniques with respect to data Engineering Research, Vol. 6, No. 6, 2015, pp. 1692-1704.
[13] D. Galar, A. Thaduri, M. Catelani, L. Ciani, Context Awareness for
tabulated in the Diagnosis ES. Maintenance Decision Making: A Diagnosis and Prognosis Approach,
Measurement, Elsevier, Vol. 67, 2015, pp. 137-150.
V. CONCLUSION [14] J. Aguilar, F. Rivas, Introducción a las Técnicas de Computación
Inteligente, 1st Edition, Meritec Editorial, Mérida, Venezuela 2001.
A Diagnosis ES that uses CBM techniques to guide [15] B. Tormos, Diagnóstico de Motores Diésel Mediante el Análisis de
maintenance optimally and that is embedded within a CMMS Aceite Usado, en Sistema de Diagnóstico Automático de Motores
for diesel engines has been created. Basado en el Análisis de Aceite, 1st Edition, Reverté Editorial,
Barcelona, España, 2005, pp. 315-351.
The ES developed for fault diagnosis facilitates the work [16] Hyundai, Diesel Engine D4EA. Bosch Common Rail, Shop Manual
of monitoring and diagnosis of Hyundai Diesel Engine CRDi Supplement., Korea, 2000.
2.0, and guides the decision-making about their maintenance. [17] Concho, I., Vergara, M., Rivas, F., Chica, F. and Rivera, N., An Expert
System Application for Diesel Engines Diagnosis, 6th European
The Diagnosis ES presented, being integrated with CBM Conference of Computer Science (ECCS '15), Rome, Italy. 2015, pp.
techniques and a CMMS for diesel engines, takes maintenance 195-201.
management and in turn to asset management to another level
that considers a holistic view of the condition of the diesel
engine. Ileana Concho Ríos. Mechanical Engineer from
Universidad de Los Andes, Mérida, Venezuela
ACKNOWLEDGMENT (2012), Graduate Student of Maintenance
Engineering at Universidad de Los Andes,
Authors want to thanks the support given to this project by Mérida, Venezuela (2015). Currently working as a
the Secretaría de Educación Superior, Ciencia, Tecnología e Maintenance Engineer at Laboratorios Valmorca,
Mérida, Venezuela (2015 to present). With
Innovación of Ecuador and Prometeo Program. experience in conducting research projects
focused on different topics of mechanical and
REFERENCES maintenance engineering using tools like Artificial Intelligence, considering
Computerized Maintenance Management Systems (CMMS), Condition Based
[1] S. Ballester, P. Olmeda, V. Macián, B. Tormos, El Mantenimiento de Maintenance (CBM) and Preventive and Predictive Maintenance. With
las Flotas de Transporte, Técnica Industrial Journal, La Industria del several scientific articles in journals and international conference
Turismo, Vol. 247, 2002, pp. 42-47. proceedings. With several scientific projects developed in different areas of
[2] T. Bangemann et al, PROTEUS – Creating Distributed Maintenance engineering. Currently developing a CMMS for Diesel Engines that integrates
Systems through an Integration Platform, Computers in Industry, Diagnosis Expert Systems for Diesel Engines and MBC techniques.
Elsevier, Vol. 57, No. 6, 2006, pp. 539-551.
[3] E. Levrat, B. Iung, TELMA: A Full E-Maintenance Platform, Proc. Mary Vergara. PhD in Industrial Engineering specifically in Mechanical
Second World Congress on Engineering Asset Management, Nancy Engineering Design and Manufacturing, She was graduated in Mechanical
Université, Faculté des Sciences, Vandoeuvre, France, 2007. Engineering from the Universidad de Los Andes in 1991 and Master degree
[4] J. Szanto, I. Nagy, Integration of Fault Diagnostic Technologies Into A in Maintenance Engineering. She has directed, implemented and evaluated
Complex Condition Monitoring System and Its Practical Results, 4th several of undergraduate, Master and Doctoral projects in her areas of
World Congress on Maintenance, Haikou, China, 2008. interest: Mechanical Design, Mathematics and Numerical Simulation of
[5] E. Simeón, A. Álvares, R. Ribeiro, An Expert System for Fault Mechanical Systems, a Posteriori Error assessment using finite element
Diagnostics in Condition Based Maintenance, ABCM Symposium Series method, Biomechanics, Intelligent Systems Application, Analysis and Fault
in Mechatronics, Vol. 4, 2010, pp. 304-313. Detection, Maintenance and Mechanical Vibrations Study. She has been
[6] X. Liu, F. Feng, A. Si, Condition Based Monitoring, Diagnosis and evaluator of various conferences, presentations at international scientific
Maintenance On Operating Equipments of a Hydraulic Generator Unit, conferences and journal papers. Also has evaluated, authorized and
IOP Publishing, 24th IAHR Symposium on Hydraulic Machinery and accreditated for various Graduate in Mechanical Engineering and Industrial
Systems, Vol. 15, No. 4, 2012, pp. 1755-1315. Maintenance programs. She has held various academic and administrative
[7] S. Singh, D. Galar, D. Baglee, S. Bjorling, Self-Maintenance positions at the Universidad de Los Andes for 22 years.
Techniques: A Smart Approach towards Self-Maintenance System,
International Journal of System Assurance Engineering and Francklin Rivas-Echeverría. Systems Engineer
Management, Vol. 5, No. 1, 2014, pp. 75-83. (1993), Magister Scientiae in Control Engineering
[8] K. McKee, G. Forbes, I. Mazhar, R. Entwistle y I. Howard, A Review of (1996), Doctor in Applied Sciences (2000). Full
Machinery Diagnostics and Prognostics Implemented on a Centrifugal time professor at Universidad de Los Andes (ULA),
Pump, Engineering Asset Management 2011, 1st Edition, Springer Venezuela, Invited Research at Pontificia
Editorial, London, England, 2014, pp. 593-614. Universidad Católica del Ecuador-sede Ibarra with
[9] Sisteplant [online], Smart Maintenance: PRISMA GMAO (2014), Prometeo Program, Ecuador. President of the
http://www.sisteplant.com/es/soluciones/innovative-technologies/smart- Board of Directors of diverse national and
maintenance-prisma-cmms/. Access: July 13, 2015. international consortiums. Founding member and
Coordinator for the ULA's Intelligent Systems Laboratory. More than 230