Abstract:
A general purpose expert system architecture for diagnosing faults in any one of a plurality of machines includes a machine information database containing information on characteristics of various components of the machines to be diagnosed and a sensory input database which contains vibration data taken at predetermined locations on each of the machines. The system knowledge base contains a plurality of general rules that are applicable to each of the plurality of machines. The generality of diagnosis is accomplished by focusing on components that make up the machine rather than individual machines as a whole. The system architecture also permits diagnosis of machines based on other parameters such as amperage, torques, displacement and its derivatives, forces, pressures and temperatures. The system includes an inference engine which links the rules in a backward chaining structure.

Description:
FIELD OF INVENTION 
     The present invention relates generally to computerized methods and apparatus for maintaining machines and more particularly to method of and a general purpose expert system for diagnosing machine problems. 
     BACKGROUND OF INVENTION 
     No machine, however well designed and constructed, can last indefinitely. Whenever there are moving parts, there will be wear and degradation of machine components leading to reduced performance quality and ultimate breakdown. The period between installation of a new machine and its final scrapping due to lack of availability of cost-effective repair or obsolescence may be termed the &#34;useful life&#34; of the machine. Prolonging the useful life of machines and keeping the machines operating smoothly in healthy condition during their useful life periods have been areas of special interest to maintenance personnel in the manufacturing industry. This invention addresses maintenance issues by utilizing a methodology by which diagnostics, and hence smooth operation, of machines can be better accomplished. Though a wealth of literature is available in the area of machine tool diagnostics, ranging from repair manuals provided by original equipment manufacturers to specialized books by experienced consultants, the generality of the knowledge engineering approach described herein is believed to be new. 
     Sensor based analysis has become an important part of the maintenance management program for detecting machine condition changes in many manufacturing facilities. With the help of such an analysis, one can monitor a machine&#39;s condition, identify problems before major breakdowns occur, predict up-time, and plan for maintenance or repair work when it is most convenient in an effort to minimize production downtime. However, several years of expertise is usually needed before a machine maintenance person can fully utilize the power of sensor based analysis. A method of capturing and organizing that expertise in a knowledge engineering framework is described herein which enables inexperienced, or even new mechanics to effectively and efficiently diagnose machine problems. 
     While the present invention was conceived for the purpose of diagnosing machines making automobile parts, it is equally applicable to machines in the aerospace industry, ship building industry and other manufacturing businesses engaged in the production of medium and heavy duty products. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, an expert system is provided which comprises in addition to a commercially available inference engine, three unique modules. These modules are a Machine Information Database (MID), a Sensory Input Database (SID), and a Knowledge Base (KB). 
     The MID module contains information describing each of the major components of the machine, the relationship to one another, and the physical features of those components. For example, there may be descriptions about motors, pulleys, belt-drives, gear-trains, head-stocks, and jackshafts as some of major components that make up a machine. There are further descriptions of those components such as length of the belt, the diameter of the pulleys and the number of teeth on the gears. Additionally, the location of sensory data measurement points are specified in the MID as well the direction of measurement of the data. 
     The SID comprises sensory data collected at different points on the machine being diagnosed. Vibration data is used as an example of sensory data for the purposes of discussing the present invention. Vibration data contains frequencies and related vibration amplitudes associated with those measurement points. The data is collected by a mechanic using a portable hand-held accelerometer and recorder and is transferred to a computer where the data is converted to a flat file. The data in the flat file is subsequently converted to a form suitable for the knowledge engineering tool. 
     The KB constitutes the principal module of the system and it contains a rule base comprising the rules of vibration analysis as well as a fact base which contains dynamic information obtained from the MID and SID. This information is placed in the fact base each consultation with the expert system upon identification by the operator of the machine to be diagnosed. The fact base also contains the static facts describing default parametric values such as precision levels of various machine components. These default values will be used unless the operator provides parametric values of the components for the machine to be diagnosed. The KB is the heart of the expert system and may contain hundreds or thousands of rules that make up the expertise of the system. For example, one of the rules might be 
      &#34;If a component is suspected to be faulty, and the phase difference across that component is low, then do the following three things: (1) rule out the possibility of misalignment of that component; (2) postpone consideration of unbalance of components that are connected to this one; and (3) pursue the next most likely fault with the component being handled.&#34; 
     One of the primary features of the present invention is its general purpose architecture that permits it to handle different types of machines. For example, the system can diagnose problems on a state-of-the-art grinding machine. It can also diagnose problems with other sophisticated machines such as new lathes, milling machines, drilling machines and super-finishers. The invention is equally effective in diagnosing problems with old machines. 
     An expert system in accordance with the present invention is applicable to a very broad range of problems that occur in manufacturing and assembly equipment. Unbalance, misalignment, mechanical looseness, structural weakness, resonance of components, eccentricity, cavitation of pumps, problems due to bearing wear or bearing failure, and problems with gear trains are some examples of the types of problems that the system of the present invention can handle. 
     Some of the benefits of using the expert system of the present invention for diagnosing machine problems include (a) precise identification of problem components, (b) repairs prior to catastrophic failures (c) ability to schedule preventive maintenance at convenience (d) faster diagnostics process (e) distribution of the diagnostics expertise to multiple users and plants (f) improved part quality (g) longer uptimes for the machines (h) avoidance of &#34;fixing&#34; non-problems (i) reduced scrap (j) longer useful life of capital equipment through better maintenance and (k) ability to run machines unattended. 
     The expert system of the present invention is applicable to many different machines and is therefore general purpose. The prior art expert systems are only applicable to individual machines. See for example the U.S. Pat. No. to Moore et al 4,697,243. In contrast the system of the present invention, can be used for virtually all types of machines with rotating components. It serves the purpose that would have typically required building several smaller expert systems. The generality is accomplished by focusing on the components that make up individual machines rather than by looking narrowly at specific machines. With the help of this system, it is possible to perform routine and diagnostic maintenance on a large variety of machines regardless of their age and/or function. New machines can be tested for rigorous compliance of performance standards so that repairs and replacements can be performed while those machines are still under warranty. Similarly, equipment manufacturers can employ the expert system of the present invention to test their products prior to shipment. 
     While the system of the present invention is particularly adapted to diagnose mechanical problems related primarily to the rotating components of machinery it is equally applicable to machines which use reciprocating components as long as the requisite knowledge is placed in the KB. Consequently, a vast majority of mechanical problems typically found in manufacturing and assembly plants can be diagnosed. 
     The system is also capable of locating and resolving problems with electrical systems, coolant and lubricant systems and hydraulic and pneumatic systems by incorporating sensory information in addition to or in place of the vibration data. 
     Moreover, by using permanently mounted, automatic sensors, on-line information may be linked to the SID and will permit maintenance monitoring of machines on a round-the-clock basis. Such a general purpose system may receive different types of sensory data from various strategic locations on the machine on a routine basis or on some alarms/thresholding basis. By adding further intelligence to the expert system, it can be made to control the polling of various sensors and the periodicity of the arrival of the sensory data. 
     Further, integration with existing factory controls, and networking with plant computers and maintenance management systems is readily accomplished with the system of the present invention. 
     Computer Aided Design (CAD) databases comprising machine descriptions may be linked to the MID of the present invention, thereby making machine description and design information available for direct downloading to the MID. This would permit maintenance of a centralized MID which may be shared by several plants located over distant geographical locations. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A more complete understanding of the present invention may be had from the following detailed description which should be read in conjunction with the drawings in which: 
     FIG. 1 shows the principal components of the expert system of the present invention; 
     FIG. 2 shows the general diagnostic method of the present invention; 
     FIG. 3 shows the steps of interaction between the user and the system; 
     FIG. 4 shows the calculations performed during the preprocessing phase of the MID; 
     FIGS. 4&#39; and 4A-4H show video presentations of menu driven data input screens; 
     FIG. 5 shows the signature collection and conversion steps that take place in the SID; 
     FIG. 6 shows the various steps that take place internally during a consultation between the user and the expert system; 
     FIG. 7 shows the identification of the machine and retrieval by the KB of the appropriate data from the MID; 
     FIG. 8 shows the steps that are used to organize signatures into problem groups; 
     FIGS. 9a and 9b shows a graphical representation of the threshold identification process; 
     FIG. 10 shows the steps involved in determining and ordering appropriate tests for machine fault confirmation; 
     FIG. 11 shows a schematic of a lathe drive train which is useful in understanding an application the present invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As shown in FIG. 1, the expert system architecture of the present invention comprises a Knowledge Base (KB) 10, a Machine Information Database (MID) 12 and a Sensory Input Database (SID) 14. Referring to FIG. 2, the MID and the SID provide input to the KB based on which the system generates a list of hypothesized faults as shown in block 16. The system then orders the faults on a prioritized basis as shown in block 18. As indicated in block 20, the system may request that the user perform certain tests in order to confirm one of the hypothesized faults. The confirmation occurs in block 22 and may be the identification of the most likely fault rather than an absolute conclusion. Based on the systems conclusions, the consultation is terminated. 
     FIG. 3 shows the procedure users follow when applying the invention to a maintenance problem. As indicated in block 24, the operator first enters the identification number which uniquely identifies the machine to be diagnosed. As shown in block 26, if the MID does not already contain the machine&#39;s description the operator is requested to provide the machine&#39;s description to the MID, block 28. Next, as shown in block 30, sensory input data is obtained from strategic locations on the machines to be diagnosed and converted at block 32, into a form suitable for the knowledge engineering tool being used. The present invention has been implemented using an expert system building tool available from Teknowledge, Inc. However, any of several commercially available tools which features a backward chaining inference engine may be utilized. Once the MID and SID information is available, the system is ready to run a consultation as indicated in block 34. As show in block 36 the user fixes the problems identified by the system and after the necessary repair has been performed, new sensory data is taken, block 38. If the new sensory data does not reveal any problems the consultation is concluded, block 40, otherwise the consultation is repeated with the new sensory data, block 34. 
     Referring now to FIG. 4, the MID data is input by the user, block 50. FIGS. 4&#39; and 4A-4H show the various input screens that the system presents to the user in order to acquire the necessary information. As can be seen from a review of the tables the machine description includes the following information: the components and subcomponents that comprise the machine; the rotational speeds of the components; attributes that the KB might need during a consultation (e.g., rotor diameter of a motor); the performance levels of the various measurement points (this information helps set the thresholds); spatial regions of the machine, with the components and measurement points contained in the regions (this helps the KB focus its fault search); the connectivity of the components of the machine (the knowledge system uses this information to rank possible faults and select possible tests). After the MID data is input, the data is preprocessed. The purpose of preprocessing the data is to perform arithmetical calculations and to organize the machine data. The preprocessing steps include loading machine description and necessary formulas into memory, block 52. Next all the rotating parts are identified, block 54. As shown in block 56 the preprocessor recursively locates the motors and calculates the frequencies of rotating parts relative to the driving motor. The relative frequencies are calculated as the preprocessor, starting with the motor shaft, follows the connections through the machine. This information is stored in an attributes table, block 58. While the data is being processed, simple error checking is also done. The user, however, has the main responsibility for ensuring that the machine data is correct. Hash tables or pointers are used to speed up the data retrieval. Once the preprocessor has calculated and propagated the relative frequencies for all the rotating parts, it checks to determine if all subcomponents of a component have identical rotational frequencies. If so, the frequency is represented at the component level and all individual frequencies are deleted at the subcomponent level. The relative rotational frequencies are written back to the attribute table. The attribute table now includes all the machine information, including frequencies. 
     A data compiler is invoked to convert the attribute table to a form acceptable to the knowledge engineering tool. The compiler accesses the attribute table using a link list and writes the name, connections, regions, components, component characteristics, subcomponents with all their information, and measurement points for the machine, to a file, block 60. 
     Prior to beginning the consultation, the operator uses a commercially available vibration data gathering instrument to acquire readings at specified measuring points. As indicated in FIG. 5, these measurement points (collectively called a route) are determined when a machine is set up for a vibration maintenance schedule, block 62. The data gathered, block 64, includes among others the following: (a) Frequencies and associated amplitudes of vibration, (b) Direction in which reading was taken, (c) Measurement points. 
     This data is then downloaded, block 66, to a computer that contains a suitable, commercially available vibration analysis program which will if desired display various graphical representations of the data for visual inspection by the operator. The above identified data (a)-(c) is then extracted, block converted to a form suitable for use by the knowledge engineering tool and then transferred to the knowledge base. 
     The various phases of a consultation with the expert system of this invention are shown in FIG. 6. There is a Machine Identification Phase designated 70, during which the mechanic is prompted for the machine ID number. As shown in FIG. 7, the ID number entered by the user, block 72, is used to locate a relevant file from the MID which is then stored in the knowledge base, block 74. This file contains a basic text description of the machine identified as well as the name of another file that contains the complete machine description. The text description is displayed to the user, block 76. The user is asked to confirm if this is the correct machine, block 78. If it is not, the user is asked for another machine ID number. If it is the correct machine, the complete machine description is loaded into the knowledge base, block 80. 
     Referring back to FIG. 6, a Problem Characterization phase designated 82, is entered in which the possible faults are prioritized based on the machine&#39;s history and any reported symptoms. This information is obtained through a number of question and answer sets, and is stored for future use. 
     During a Data Acquisition phase indicated at 84, signature data is acquired and then transferred to the knowledge base. Thereafter a Signature Grouping phase designated 86 is entered, in which the peaks and humps of the signature are determined and organized in order to effectively process the signature data. The analysis of the signatures is independent of the machine. Signatures are the primary evidence used in the diagnostic process performed by the expert system. Only the most recent signatures are pertinent. Historical signature readings are not relevant. 
     The Signature Grouping process is shown in greater detail in FIG. 8. The first step in signature grouping designated 88, is to determine the peaks and humps. These peaks may or may not represent a problem. Peaks must pass the following criteria: (a) the amplitude of the peak is greater than the amplitude of the smoothed average curve of the signature (a weighted average of the amplitude around each data point) multiplied by a predetermined factor, set by the expert, of for example 1.2; (b) peak amplitude is greater than the noise level. The noise level is one of two preset values such as 0.004 inches/sec. or 0.006 inches/sec.. If 70% of the amplitudes are below the lower preset value, then the lower preset value is used. Humps must pass the following criteria: (a) all portions of a hump must lie above a predetermined minimum frequency, (b) all humps must be predetermined minimum frequency width, (c) original spectrum must lie at or above the noise level for the entire width of the hump, (d) a smoothed hump must lie at least a predetermined percentage above the noise level. 
     Once the signature is broken down into peaks and humps, it is organized in a format acceptable to the knowledge engineering tool, block 90. There are four major pieces of data for each signature: the signature location, lines of resolution, direction, and maximum frequency. Then for each peak, the amplitude and center frequency are stored. For each hump the maximum amplitude, average amplitude, starting frequency, and ending frequency are stored. 
     As shown in block 92, subgroups of peaks and humps having the same frequency and direction are formed. Thereafter, as indicated in block 94, subgroups with the same spatial location on the machine are merged together. The spatial location is obtained from the MID. Merged subgroups containing less than four (4) subgroups are too small to potentially confirm an area of a machine to be a problem. Therefore such merged subgroups are disbanded and regrouped based on harmonics, as shown in block 96. Harmonics are used to identify frequencies that are echoes from parts in other areas of the machine. This is to assist in pinpointing the areas of the machine that are problems. 
     This grouping of the subgroups is accomplished as follows: (a) First the subgroups are arranged in ascending order of frequencies. (b) Next the ratio of the frequency of each subgroup to the frequency of the lowest frequency subgroup is computed. If the ratio is an integer less than a predetermined constant, such as for example, 6, then the subgroups are merged into a first group. (c) If the ratio is 6 or more, then a new ratio is computed, this time using the highest frequency considered so far in place of the frequency of the lowest frequency subgroup. If the new ratio is less than 6 then the subgroups are merged into the first group. (d) If a non-integer is obtained while computing either of the above ratios then the highest common factor of the two frequencies under consideration is determined and the frequencies under consideration are divided by this highest common factor. If the division yields integers of less than 6 then the two subgroups represented by the frequencies under consideration are merged into a second group. The aforegoing regrouping process is repeated for any remaining subgroups until no more subgroups remain. If this does not exhaust the subgroups then each of those remaining subgroups are thereafter considered groups. In the end, all the subgroups are placed in groups, block 104. The information in the fact base now includes; the groups; largest amplitude for each group; and for each group the direction, nominal frequency, types(peaks/humps). 
     As indicated in block 106 the amplitude of the signatures in the groups are compared against predetermined threshold values. The threshold values may be different from pattern to pattern. There are two parameters used in determining threshold values: the frequency of the signature pattern; and the performance level of the component on which the signature pattern appeared. The MID contains the performance level associated with the components. As shown in block 108, the performance is obtained from the MID, having been previously entered or provided by the user. If it is unknown, the performance level is automatically set to a default value of, for example, an average performance level. The other levels possible are very high, high, low, and rough performance. The knowledge base has a table for each performance level and each table contains a plurality of frequency values and corresponding acceptable threshold amplitudes. These threshold values are set by the human expert. The threshold value is then looked-up based on a signature pattern&#39;s frequency and performance level as indicated in block 110. For example, as shown in FIG. 9a, for each peak, identified as A-D, the frequency at which the peak occurs is obtained from the signature data. For example, peak D occurs at frequency f(D). Assuming that the performance of the component on which the reading at D was obtained is a high precision component, then the corresponding threshold value a(D) is obtained from the high precision table as represented by FIG. 9b. 
     If the amplitude at D is above the threshold a(D), a problem very likely exists. If any amplitude in a group is above threshold, the group is set aside as a problem group. The system then looks at other groups in the same spatial region, and checks them for amplitudes that are 80% of threshold. If one exists, then it is also marked a problem group. These are marked to contain potential problems. At this time, the type of problem is unknown. It could be any that the system can diagnose or one that it cannot. If the amplitude value is between 80% and 100% of threshold a potential problem exists. Only those groups that represent existing or potential problems are considered for further analysis. 
     Only one frequency group will be analyzed at a time. As shown in FIG. 6, block 112, the system recommends a preferred order of analyzing the frequency groups based on user supplied symptoms and associated components of the machine which exhibit the symptoms, and on the severity of possible problem as determined by the amount by which the amplitude exceeds the threshold. In other words, it is preferable to first consider those frequency groups which include components that the user identifies as exhibiting a problem, or in the absence of user input, groups that have high amplitude values. 
     After the ordered frequency groups have been determined, the expert system begins diagnosing the first frequency group, as indicated at block 114. In the block identified at 116, possible fault areas are identified based on signatures in this first group and rules associated with signatures and machine components as obtained from the MID. After the fault areas are identified, they are prioritized by the expert system as indicated at 118. This prioritization is determined, based on data provided by the user during the Problem Characteristic phase 82 and the components if any, which are identified as potential problem components by the user. 
     During the Test Batching phase indicated at block 120, the expert system determines which tests, if any, are needed to confirm the ordered faults as shown in FIG. 10, block 122. The tests are requested by the expert system in batches in order to allow the user to work more efficiently. Test batching has two benefits for the user: it reduces the number of trips to the machine to gather data; and it provides a set of tests to perform, which the technicians can schedule in a manner that minimizes the time spent dismantling the machine. The selection of tests to be performed are based on: potential fault conclusion that the test can reach, and the preconditions which must be met to perform the test. The criteria used by the expert system in determining the sequence of the tests that should be performed for each fault, block 124, is based on: (a) ease of doing a test for a normally skilled operator; (b) the likelihood that the test will help identify the fault that has the highest certainty factor (CF); (c) relation to other tests (i.e., it is best to perform a belt loosening test prior to a belt disconnect test). 
     Once the sequence of the tests is identified for each fault, the first two tests in the sequence for each of the faults are grouped, block 126 and ordered, block 128, based on the above mentioned criteria. The user is then requested to perform the first 5 tests in the ordered group of tests, block 130. The system will query the user on the results of the tests performed. The rules are applied to the input provided by the user and additions and adjustments to the faults and their rankings are made as indicated in block 132. For example, based on the test results the system may revise belief in a fault (increasing or decreasing); rule out a fault; defer consideration of a fault until everything else is ruled out or; confirm a fault. As indicated in block 134, if no one fault is confirmed, the test batching procedure is performed again, beginning at block 122, except that the tests already performed for that frequency group are discarded. Referring back to FIG. 6, as shown in block 136, once a fault is confirmed for the problem frequency group, the next problem group is analyzed beginning at block 114. If no more frequency groups remain, then a summary of all faults and necessary repair recommendation are provided, block 138 and the consultation is terminated. The summary also identifies any tests that corrected problems. On some occasions when the system is unable to confirm a fault with 100% certainty it may suggest repairs for faults having significantly high certainty or for faults for which the time to perform the repair is less than the time to do further diagnostic tests. If there is no identified problem, this is stated. Finally, information on emerging bearing problems is reported. 
     During a frequency group diagnosis, the system may decide that a certain repair action should be attempted, even if the associated fault is not confirmed. In this way it acts like the human expert who would attempt repairs even if not 100% sure. 
     Once the necessary repairs are made, then a new signature set is taken and entered in the SID. When attempting to verify that the repairs have indeed corrected the problems, the system resets most of the facts in the fact base (except for machine data, history data, and repair actions taken). The new requested signature data is processed. Any new symptom information is also processed. If no signature patterns exceed threshold, and no problem symptoms are seen then the system confirms that all problems have been fixed correctly. Otherwise, it repeats the diagnostic cycle. 
     An example of the application of the present invention to a simple machine, such as a lathe drive train, will now be described with reference to FIG. 11. Let the machine be comprised of the following components shown in FIG. 11: 
     Drive Motor, Belt-Drive-1, Belt-Drive-2, Clutch, Jackshaft, Belt-Drive-3, Work Spindle, Chuck, Live Center, Tailstock. 
     Assuming that based on user input during the Problem Characterization phase and based on information from the SID the system generates the following list of hypothesized faults; misalignment of belt drive 3, unbalance of motor and looseness of belt drive 3, the system searches for rules which would help it confirm each one of these faults. Assume that the rule base contains the following rule. 
     If: There is a high level of vibration on a component 
     and that component is not cantilevered or resonating 
     and vibration frequency matches low integral multiples of the rotational frequency of that component. 
     Then: Conclude that the component under investigation is misaligned 
     and rule out the possibility of looseness of that component. 
     Each of the conditions in the premise part of the rule is tested. Assume that based on SID information the amplitude of vibration on belt drive 3 is above threshold and given that belt drive 3 is not cantilevered or resonating, the system checks to determine if the vibration frequency is a low integral multiple (for example 2) of the speed of rotation of belt drive 3. If this is so, then the system makes two decisions: first, if confirms that the belt drive 3 is misaligned; and second, it removes the possibility of looseness of belt drive 3 from it&#39;s list of hypothesized faults. If the rule had failed, i.e. one of the conditions in the premise was not satisfied, then no conclusion would have been made and other rules would be tried in an attempt to confirm the hypothesized faults. 
     A typical consultation is attached as Appendix A. A review of this consultation may be helpful in further understanding the details of the system&#39;s functioning. ##SPC1##