SENSOR SYSTEM AND METHOD FOR IDENTIFYING A STATE OF AT LEAST ONE MACHINE
20230086842 · 2023-03-23
Inventors
Cpc classification
G06N7/01
PHYSICS
G07C3/00
PHYSICS
F02C7/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
A sensor system for identifying a state of at least one machine includes one or more sensors for acquiring measured values of the at least one machine, at least one communication interface, and an evaluation unit configured to acquire a plurality of data sets containing measured values of the one or more sensors, select a portion of the data sets by active learning, and provide the selected portion of the data sets to the at least one communication interface for the purpose of identifying the state of the at least one machine.
Claims
1. A sensor system for identifying a state of at least one machine, the sensor system comprising: one or more sensors configured to acquire measured values of the at least one machine; at least one communication interface; and an evaluation unit configured to: acquire a plurality of data sets containing the measured values of the one or more sensors; select a portion of the plurality of data sets by active learning; and provide the selected portion of the plurality of data sets to the at least one communication interface to identify the state of the at least one machine.
2. The sensor system of claim 1, wherein the evaluation unit is further configured to specify an order for the selected portion of the plurality of data sets by active learning.
3. The sensor system of claim 1, wherein the evaluation unit is further configured to: divide the plurality of data sets into at least two groups with regard to at least one parameter of the plurality of data sets by a separation line; and select the portion of the plurality of data sets based on a distance between the parameters of the respective data sets and the separation line.
4. The sensor system of claim 1, wherein the evaluation unit is further configured to receive a classification of the plurality of data sets provided at the at least one communication interface with regard to the state of the at least one machine.
5. The sensor system of claim 4, wherein the evaluation unit is further configured to analyze the classification of the plurality of data sets in order to acquire at least one parameter of a respective data set.
6. The sensor system of claim 5, wherein the evaluation unit is further configured to use the acquired at least one parameter to train a machine learning model.
7. The sensor system of claim 6, wherein the evaluation unit is further configured to use the trained machine learning model to classify further data sets containing measured values.
8. The sensor system of claim 1, wherein the at least one machine is at least one gas turbine engine.
9. A method for identifying a state of at least one machine, the method comprising: generating measured values of the at least one machine by one or more sensors; acquiring, with an evaluation unit, a plurality of data sets containing measured values of the one or more sensors; selecting, with the evaluation unit and by active learning, a portion of the plurality of data sets; providing the selected portion of the plurality of data sets to at least one communication interface; and identifying the state of the at least one machine using the provided selected portion of the plurality of data sets.
10. The method of claim 9, further comprising: specifying an order for the selected portion of the plurality of data sets by the active learning.
11. The method of claim 9, further comprising: receiving, by the evaluation unit, a classification of the plurality of data sets provided at the at least one communication interface with regard to the state of the at least one machine, training, by the evaluation unit, a machine learning model on the basis thereof; using, by the evaluation unit, the trained machine learning model to classify further data sets containing measured values; and servicing the corresponding machine depending on the classification of the further data sets.
12. A non-transitory computer program product comprising instructions which, when executed by one or more processors, cause the one or more processors to: generate measured values of at least one machine by one or more sensors; acquire a plurality of data sets containing measured values of the one or more sensors; select, by active learning, a portion of the plurality of data sets; provide the selected portion of the plurality of data sets to at least one communication interface; and identify a state of the at least one machine using the provided selected portion of the plurality of data sets.
13. The method of claim 9, further comprising: dividing, by the evaluation unit, the plurality of data sets into at least two groups with regard to at least one parameter of the plurality of data sets by a separation line; and selecting, by the evaluation unit, the portion of the plurality of data sets based on a distance between the parameters of the respective data sets and the separation line.
14. The method of claim 9, further comprising: receiving, by the evaluation unit, a classification of the plurality of data sets provided at the at least one communication interface with regard to the state of the at least one machine.
15. The method of claim 14, further comprising: analyzing, by the evaluation unit, the classification of the plurality of data sets in order to acquire at least one parameter of a respective data set.
16. The method of claim 15, further comprising: using, by the evaluation unit, the acquired at least one parameter to train a machine learning model.
17. The method of claim 16, further comprising: using, by the evaluation unit, the trained machine learning model to classify further data sets containing measured values.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Embodiments will now be described by way of example with reference to the figures, in which:
[0023]
[0024]
[0025]
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[0030]
DETAILED DESCRIPTION
[0031]
[0032]
[0033] During operation, the core air flow A is accelerated and compressed by the low-pressure compressor 14 and directed into the high-pressure compressor 15, where further compression takes place. The compressed air expelled from the high-pressure compressor 15 is directed into the combustion device 16, where it is mixed with fuel and the mixture is combusted. The resulting hot combustion products then propagate through the high-pressure and the low-pressure turbines 17, 19 and thereby drive the turbines, before being expelled through the nozzle 20 to provide a certain propulsive thrust. The high-pressure turbine 17 drives the high-pressure compressor 15 by a suitable connecting shaft 27. The fan 23 may provide the bulk of the propulsive thrust. The epicyclic planetary gear box 30 is a reduction gear box.
[0034] It is noted that the terms “low-pressure turbine” and “low-pressure compressor” as used herein may be taken to mean the lowest-pressure turbine stage and lowest-pressure compressor stage (e.g., not including the fan 23) respectively, and/or the turbine and compressor stages that are connected together by the connecting shaft 26 with the lowest rotational speed in the engine (e.g., not including the gear box output shaft that drives the fan 23). In some documents, the “low-pressure turbine” and the “low-pressure compressor” referred to herein may alternatively be known as the “intermediate-pressure turbine” and “intermediate-pressure compressor”. Where such alternative nomenclature is used, the fan 23 may be referred to as a first, or lowest-pressure, compression stage.
[0035] Other gas turbine engines in which the present disclosure may be used may have alternative configurations. For example, such engines may have an alternative number of compressors and/or turbines and/or an alternative number of connecting shafts. As a further example, the gas turbine engine shown in
[0036] The geometry of the gas turbine engine 10, and components thereof, is/are defined by a conventional axis system, which includes an axial direction (which is aligned with the axis of rotation 9), a radial direction (in the direction from bottom to top in
[0037] A plurality of sensors is arranged on the gas turbine engine 10, of which a plurality of sensors 60-62 arranged at different points on the gas turbine engine 10, specifically temperature sensors for measuring temperatures, are illustrated here by way of example.
[0038]
[0039] The evaluation unit 52 is configured to receive a plurality of data sets, each data set containing measured values of the sensors 60-62. The evaluation unit 52 is further configured to select a portion of the data sets by active learning. Furthermore, the evaluation unit 52 is configured to provide the selected portion of the data sets to the communication interface 58 for the purpose of identifying the state of at least one machine, in this case the gas turbine engine 10.
[0040] At least one machine learning model 51 is stored in a memory 53 of the evaluation unit 52, in particular a plurality of machine learning models 51 are stored or may be stored. The plurality of machine learning models 51 may represent a plurality of instances of the same machine learning model. The evaluation unit 52 is communicatively coupled to the sensors 60-62 via a communication interface 58 in order to acquire data, specifically measured values, from them. Furthermore, the evaluation unit 52 is communicatively coupled to at least one interface 81 (via the communication interface 58 or a further communication interface). In the present example, the interface 81 is in the form of a graphical user interface (GUI) and may be displayed on a display 80.
[0041] Via the interface 81, a user may classify one or more data sets selected by the active learning. In this example, the user may also select that portion of the measured values in the respective data set which is the reason for the selected classification. For example, the user may decide whether a respective data set includes measured values indicative of a particular state of the gas turbine engine 10, such as the wear or defect of a component. The sensor system 50 may receive this classification (and optionally the selected portion of the measured values) of the respective data set via the communication interface 58 and may thus train the machine learning model 51.
[0042] The machine learning models 51 are designed for machine learning and in the present example include a random forest and/or an artificial neural network. The sensor system 50 also includes a further machine learning model 57 which will be explained in yet more detail below. Based on the trained machine learning models 51, 57, data sets containing measured values may be classified in order to automatically make data-driven decisions, for example, to trigger maintenance work.
[0043] The memory 53 also stores instructions 54 which are part of a computer program product which causes a processor 55 of the evaluation unit 52 to carry out the method shown in
[0044] The evaluation unit 52 also includes a selector 56 (stored, for example, in the memory 53). The selector 56 is configured for active learning. For this purpose, the selector 56 is configured, for example, to select one or more data sets (as a subset) from a multiplicity of data sets based on a specified rule, for example, to select in each case that data set which is to be used for the next classification, for example, for which the selector 56 determines the greatest probability of this data set having the strongest training effect for the machine learning model 51. The selector 56 makes this data set available to the interface 81 via the communication interface 58 in each case. Furthermore, the selector 56 may provide selected data sets via a software-based communication interface 59, e.g., to one or more machine learning models 51, 57. The selector 56 determines, for example, an order for the selected data sets.
[0045] The evaluation unit 52 is optionally stationed on the ground and the gas turbine engine 10 may be moved relative thereto.
[0046]
[0047] A database 100 stores measured values from the sensors 60-62 in the form of a multiplicity of time series and as raw data. The time series originate, for example, from a plurality of flights of the gas turbine engine 10, from the plurality of gas turbine engines 10 of the aircraft 8, and/or from gas turbine engines 10 of a plurality of aircraft 8 (or, e.g., from a plurality of machines). The transmission from the sensors 60-62 to the database 100 takes place, for example, via a data cable or wirelessly, (such as via GSM or another mobile communication standard), in particular via the communication interface 58. The database 100 is stored in the memory 53, for example.
[0048] Optionally, the data stored in the database 100 are preprocessed and stored in a further database 101, which may also involve a transient flow of data. For example, data that are not of interest cannot be transferred in order to simplify further processing.
[0049] Optionally, the measured values are preprocessed further and stored in a further database 102 in order analyze the measured values with regard to suitable time series. This analysis takes place in block 117. In this case, data sets containing measured values are selected from a larger number of data sets.
[0050] In block 117, suitable candidates are selected from data sets, in particular each with a time series from a sensor 60-62 or each with a plurality of time series (in particular spanning the same time period) from a plurality of the sensors 60-62. The portion of the data sets is selected in this case by active learning. The selected portion of the data sets is provided to the communication interface 58 for the purpose of identifying the state of the at least one machine 10.
[0051] In the case of data that form the basis of a decision-making process, measured values in specific time intervals may allow particularly precise conclusions to be drawn about the state of the sensor or a machine monitored by the sensor. In particular, if a gas turbine engine sensor is involved, for example, certain signatures in the data may be an indication of a deteriorating state of the sensor or of a component that is monitored or may be monitored thereby.
[0052] The selected candidates or pointers to them are optionally stored in a database 110.
[0053] For example, an import script retrieves these candidates from the database 102 (or the database 101) in block 118 and provides them to a block 111 (optionally via a further database 106).
[0054] In block 111, a classification data unit and a selected portion of the measured values of the respective candidate are respectively acquired for all or for some of the candidates. The classification data units indicate a classification of the candidate into one of a plurality of predefined classes. The classification data units and/or the selected portions of the measured values are provided by one or more users in this case. This takes place, for example, via the interface 81 and/or the communication interface 58.
[0055] The classification data units and selected portions of the candidates are stored in a database 108 and provided to a block 112. In block 112, one instance of the machine learning model 51 is trained (e.g., per user) on the basis of the classification data units and selected portions of the candidates that were provided by the user. For this purpose, properties of the selected portion of the measured values are extracted in each case in the form of parameters. Optionally, the extracted parameters and/or values calculated therefrom, e.g., ratios of two parameters, are then the input parameters for the training. Examples of such parameters will be explained further below in connection with
[0056] The data stored in the database 108 are provided to a block 113 which may also access the database 107. In block 113, the (optional) higher-level machine learning model 57 is generated. The higher-level machine learning model 57 optionally corresponds to the machine learning model 51, but is trained, for example, with the (optionally weighted and/or selected) input parameters from a plurality of instances of the machine learning model 51.
[0057] The higher-level machine learning model 57 and/or the input parameters thereof is/are stored in a database 109 (which is stored, for example, in the memory 53).
[0058] In optional block 114, the generation of the higher-level machine learning model 57 is displayed on a user interface.
[0059] The database 103 includes the data from the database 102 to which optional selection or correction scripts have been applied. Alternatively, instead of the databases 102 and 103, only the database 102 is provided.
[0060] In block 115, the higher-level machine learning model 57 is applied to the measured values in the database 103 (or 102) in order to classify the measured values. The results of the classification from block 115 are stored in a database 104, optionally also data from the database 103 (or 102).
[0061] In block 116, data-driven decisions are made, for example, the execution of maintenance work is triggered. For example, it was recognized from the classification that one of the sensors 60-62 or a component of the gas turbine engine 10 (or, e.g., a machine monitored by the sensor system 50) that is monitored by the sensors 60-62 is defective and needs to be replaced. Optionally, a message indicating a decision is generated and transmitted, e.g., by e-mail.
[0062] The data on which the decisions are based are optionally stored in a database 105. The databases 100 to 104 (which may also be logical steps through a flow of data) are optionally part of an engine equipment health management, EHM, of the gas turbine engine 10 and/or are stored in the memory 53. In particular, the database 105 may be stationed on the ground, for example. Furthermore, it should be noted that the databases 100, 101, 102, 103, 104, and/or 105 (optionally all databases) may have separate physical memories or alternatively may be databases of a logical architecture, wherein e.g., a plurality or all of the databases have the same physical memory.
[0063] One or more of the blocks 111 to 118, in particular all of the blocks 111 to 118, may be stored in the memory 53 in the form of instructions 54 and may be executed by the processor 55.
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[0065]
[0066] Furthermore, a selected portion 71 of the measured values 70 is illustrated in
[0067]
[0068] The parameters may be a maximum value, a minimum value, a median, a mean average, a variance, the sum of the squared individual values, the length of the selected portion in the time direction, an autocorrelation or a parameter derived therefrom, the number of values above or below the mean average, the longest time interval above or below the mean average, the sum of the gradient sign changes, a gradient, a standard deviation, and/or a number of peaks. Some of these parameters are graphically highlighted in
[0069]
[0070] Optionally, clusters of data points (in particular in the selected portion) are determined in the multidimensional representation and e.g., the distances of the clusters from one another and/or the sizes, e.g., radii, of the clusters and/or the number of data points they contain are determined.
[0071]
[0072] Act 51 includes providing a trained machine learning model, in particular a trained higher-level machine learning model 57.
[0073] For this purpose, for example, a method for training the machine learning models 51 is carried out, including acts S10 to S14.
[0074] Act S10 includes generating measured values of at least one machine, in particular at least one gas turbine engine, using the one or more sensors 60-62, the measured values 70 being acquired in particular in the form of time series data and in particular indicating measured values of one or more gas turbines 10.
[0075] Act S11 includes acquiring, by the evaluation unit 52, data sets containing measured values 70 obtained by the one or more sensors 60-62.
[0076] Act S12 includes selecting, with the evaluation unit 52 and by active learning, a portion of the data sets.
[0077] Act S13 includes providing, in particular by the evaluation unit 52, the selected portion of the data sets at the communication interface 58 (in particular for display at the interface 81) for the purpose of identifying the state of the at least one machine.
[0078] Act S13 may also include receiving, by the evaluation unit 52, classification data units relating to the measured values 70, the classification data units received by the evaluation unit 52 relating to the data sets provided at the communication interface 58. Act S13 also includes receiving, by the evaluation unit 52 and for each of the classification data units, a selected portion 71 of the measured values 70.
[0079] Act S14 includes training, by the evaluation unit 52, one or more machine learning models 51 on the basis of the classification data units and the selected portions 71 of the measured values 70, the machine learning models 51 may include an artificial neural network.
[0080] Optionally, a plurality of machine learning models 51, e.g., a plurality of instances of the same type of machine learning model 51, are trained (e.g., by each of the above acts being carried out by a plurality of users) and a higher-level machine learning model 57 is calculated from the plurality of machine learning models 51 (instances).
[0081] Act S2 includes classifying, by the evaluation unit 52, data sets containing measured values 70 acquired by one or more sensors 60-62, using the at least one machine learning model 51 and/or the higher-level machine learning model 57.
[0082] The optional act S3 includes generating, by the evaluation unit 52 and on the basis of the classification of the data sets of the measured values 70, a command which indicates performance of maintenance work.
[0083]
[0084] The data sets stored in the database 102 are provided to the block 117 (which is, for example, the block 117 explained in connection with
[0085] The block 117 provides (in particular successively) a portion of the data sets stored in the database 102 as candidates to the interface 81 via a communication connection K2. The measured values of the respective candidates are displayed via the interface 81 (communication connection K3), with the result that a user may classify them by making appropriate inputs via the interface 81. In addition to the classification, the user selects a portion of the measured values in the respective data set that includes fewer measured values than the entire corresponding data set. This is the portion of the measured values which gives rise to the respective classification. The user may be an expert who may identify anomalies in the data sets with a particularly good hit rate based on their experience (but who is unable to classify the potentially enormous amounts of data sets from the database 102). An anomaly may be exceeding a threshold value, a specific trend, a sudden change, or the like.
[0086] Block 112.1 represents, for example, part of block 112 explained with reference to
[0087] Based on the features determined in block 112.1 (which are transmitted via a communication connection K5), a further machine learning model is created in block 112.2, for example, in the form of a random forest classifier, a logistic regressor, or a so-called support vector machine. This machine learning model is designed to predict whether or not a further (new, unclassified) data set has an anomaly. Block 112.2 represents, for example, part of block 112 explained with reference to
[0088] The flow of information for training machine learning models takes place via the communication connections K4 and K5 (dashed lines).
[0089] The next candidate to be displayed to the user in each case is determined by active learning. For this purpose, for example, the trained algorithm for learning features is used for each candidate (e.g., each data set stored in the database 102) in order to determine features of the candidates. Furthermore, the classification learning algorithm is used to determine which of the candidates is the one that promises the greatest learning effect (is the newest in terms of its features, so to speak). For this purpose, for example, a distance to a separation boundary between different classes and/or to a separation boundary of a single class is determined. Alternatively, or additionally, the maximum information content that is relevant to the machine learning model is determined. For example, an entropy value is determined.
[0090] For this purpose, blocks 112.1 and 112.2 are connected via communication connections K7, K8.
[0091]
[0092]
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[0094] The separation line may be curved or straight, and also part of a multi-dimensional separation boundary.
[0095] The disclosure is not limited to the embodiments described above, and various modifications and improvements may be made without departing from the concepts described herein. Any of the features may be used separately or in combination with any other features, unless they are mutually exclusive, and the disclosure extends to and includes all combinations and sub-combinations of one or more features that are described herein.
[0096] In particular, instead of the gas turbine engine 10, another machine, such as a motor and/or engine, (e.g., a piston engine), may also be used.
LIST OF REFERENCE SIGNS
[0097] 8 Aircraft [0098] 9 Main axis of rotation [0099] 10 Gas turbine engine [0100] 11 Core engine [0101] 12 Air inlet [0102] 14 Low-pressure compressor [0103] 15 High-pressure compressor [0104] 16 Combustion device [0105] 17 High-pressure turbine [0106] 18 Bypass thrust nozzle [0107] 19 Low-pressure turbine [0108] 20 Core thrust nozzle [0109] 21 Engine nacelle [0110] 22 Bypass duct [0111] 23 Fan [0112] 24 Stationary support structure [0113] 26 Shaft [0114] 27 Connecting shaft [0115] 30 Gear box [0116] 50 Sensor system [0117] 51 Machine learning model [0118] 52 Evaluation unit [0119] 53 Memory [0120] 54 Instructions [0121] 55 Processor [0122] 56 Selector [0123] 57 Higher-level machine learning model [0124] 58, 59 Communication interface [0125] 60-62 Sensor [0126] 70 Data (measured values) [0127] 71 Selected portion [0128] 80 Display [0129] 81 Interface [0130] 100-110 Database [0131] 111-119 Block [0132] A Core air flow [0133] B Bypass air flow [0134] K1-K8 Communication connection [0135] L Separation line