Experimental studies on intelligent fault detection and diagnosis using sensor networks on mechanical pneumatic systems

Fault is a undesirable factor in any mechanical/pneumatic system. It affects the efficiency of system operation and reduces economic benefit in industry. The early detection and diagnosis of faults in a mechanical system becomes important for preventing failure of equipment and loss of productivity and profits. In this paper, we present our ongoing research results on intelligent fault detections and diagnosis (FDD) on mechanical/pneumatic systems. Using data from sensors and sensor network in an integrated industrial system, our proposed FDD methodology provides the analysis of necessary sensory information (for example, flow rates and pressure, as well as other digital sensor data) for the detection and diagnosis of system fault. In this experimental study, the leakage of pneumatic cylinder was the "fault." It was shown that the FDD analysis was able to make diagnosis of leakage both in location and size of the fault. In addition, the systematic fault and localized faults can be detected separately. The proposed wavelet method gives rise to the fingerprint analysis to recognize the patterns of the flow rate and pressure data - a very useful tool in intelligent fault detection and diagnosis.