Abstract:
A diagnostics subsystem for performing predictive diagnostics on a machine such as a vacuum pump. The subsystem has one or more parameter sensors providing measurable data, a process model for modelling machine operation and generating at least one estimated operating parameter, a comparator for comparing the sensed operating parameter with the estimated operating parameter; discontinuous signal injection means for injecting a discontinuity into the model to maintain sliding mode operation in the model; and means for analyzing the discontinuous injection signal for trends indicative of a fault in the machine.

Description:
CLAIM OF PRIORITY 
     This application is a U.S. National Stage Application of and claims priority to International Application Number PCT/GB2005/004445; filed Nov. 17, 2005, which claims priority to United Kingdom Application No. 0425458.7, filed Nov. 18, 2004. International Application Number PCT/GB2005/004445 and United Kingdom Application No. 0425458.7 are expressly incorporated herein by reference in their entirety. 
     FIELD OF THE INVENTION 
     This invention relates to a diagnostics subsystem for performing predictive diagnostics on a machine such as a high-speed rotating machine. It is particularly useful in combination with a machine such as a vacuum pump. 
     BACKGROUND 
     As machines become more complex and valuable, there is a greater need to protect them, and the systems they support, from the consequences of breakdown. This is relevant in the semiconductor industry, for example, where machine failure can contribute to the loss of a very valuable batch of wafers. Dry vacuum pumps have been successfully used in the semiconductor industry. Nonetheless, the harsh nature in many semiconductor processes creates a challenge for condition monitoring of these systems (see Troup et al. (1988), Dry pumps operating under harsh conditions in the semiconductor industry,  Journal of Vacuum Sci. Technol , Vol. 7, 2381-2386). Any diagnostic scheme should be able to operate under all conditions and be able to detect faults, creating an alarm to warn the user that maintenance must be conveniently scheduled before catastrophic loss occurs. 
     Sliding mode techniques have been used widely for fault detection schemes in recent years. Their main advantage is that they exhibit fundamental robustness against certain kinds of parameter variations. The design procedure is characterised by two phases: selection of an appropriate surface where the system will demonstrate desired dynamics and selection of an injection signal that will force the system to reach and maintain its sliding motion. 
     A number of engineering and biomedical applications have used sliding mode observers in order to recreate fault signals. Examples can be found in Jones et al. (2000),  Aspects of diagnostic schemes for biomedical and engineering systems , IEE Proc.-Sci. Meas. Technol, Vol. 147, No. 6. A particular sliding mode observer for fault detection and isolation is described by Edwards et al. (1999), in  Sliding mode observers for fault detection and isolation , Automatica, Vol. 36, 541-553. The novelty of the approach is that the observer attempts to reconstruct the fault signals rather than detect the presence of a fault through a residual signal. The proposed observer is designed to maintain the sliding motion, even in the presence of faults, which are detected by analysing the so-called equivalent output injection signal obtained from the discontinuous injection signal required to maintain sliding. The equivalent injection signal is thus not the injection signal applied to the observer but represents the injection required, on average, to maintain sliding motion. The equivalent injection signal can be readily obtained from by appropriate filtering of the applied, usually discontinuous, injection signal required. An alternative sliding mode observer scheme for monitoring is described in Hermans et al (1996),  Sliding mode observer for robust sensor monitoring , Proceedings of the 13 th  IFAC World congress, pp. 211-216. In that document, a design approach is adopted whereby, when a fault occurs, the observer is disturbed from its surface and sliding ceases. However, the sliding mode control theory indicates such an approach is difficult to implement since the observer is designed in such a way in order to keep the system always in sliding motion. In addition, the choice of gain to maintain sliding motion from the theory is often conservative. Therefore, it is difficult to ensure a fault induces a break in sliding. 
     Many real, reliable sensors are not commercially or technically viable in corrosive, toxic, or high-temperature environments within rotating machines (e.g. inside a semiconductor process vacuum pump). 
     SUMMARY OF THE INVENTION 
     According to a first aspect of the present invention, a diagnostics subsystem is provided for performing predictive diagnostics on a machine, the subsystem comprising: at least one sensor for providing at least one sensed operating parameter of the machine; a process model for modelling operation of the machine and generating at least one estimated operating parameter, comparison means for comparing the sensed operating parameter with the estimated operating parameter; discontinuous signal injection means for injecting a discontinuity into the model to maintain sliding mode operation in the model in which the difference between the estimated operating parameter and the sensed operating parameter tends to zero; and analysis means for analysing the discontinuous injection signal for an indication or indications (e.g. a trend or trends) indicative of a fault in the machine. 
     There may be a number of sensors. The sensors give a set of sensed operating parameters, such as temperature in a pump and current in a pump motor. Other possible sensors can include: pressure or pressure difference; mass flow rate (e.g. measured by a fluid flow meter); vibration (as measured by an accelerometer); acoustic parameters measured using a microphone; and derivations of such parameters (e.g. noise spectrum frequency/distribution or deviation from normal noise spectrum). Preferably the process model generates a corresponding set of estimated operating parameters and the comparison means compares sensed operating parameters with corresponding estimated operating parameters. 
     The discontinuous signal injection means are arranged to generate an injection signal as a function of the sign of an output of the comparison means, and to thereby cause the difference between each sensed operating parameter and its corresponding estimated operating parameter to tend to zero in the sliding mode operation. The magnitude of the injection signal is not important, provided it is sufficiently large to keep the model in sliding mode. 
     The analysis means preferably comprise means for estimating a deviation (or alternatively a trend) in the discontinuous injection signal from a nominal level. The deviation from the nominal level may be a simple crossing of a pre-set threshold, but may alternatively be a statistically significant deviation. 
     In accordance with a second aspect of the invention, a pump is provided having at least one sensor for sensing an operating parameter of the pump and a diagnostics subsystem comprising: a process model for modelling operation of the pump and generating at least one estimated operating parameter including an inferred parameter, comparison means for comparing the sensed operating parameter with the estimated operating parameter; discontinuous signal injection means for injecting a discontinuity into the model to maintain sliding mode operation in the model in which the difference between the estimated operating parameter and the sensed operating parameter tends to zero; and analysis means for analysing the discontinuous injection signal for a deviation in the inferred parameter from a nominal value, which is an indication of a fault in the pump. 
     The analysis means are preferably arranged to identify a change in the discontinuous injection signal required to maintain sliding mode operation in the model and are arranged to generate a fault signal in response to such a change. 
     The invention in its preferred embodiment operates by using sliding mode observers designed to infer the values that would be obtained from real sensors, and therefore act as “virtual sensors” which can aid in machine diagnosis. 
     By these and other means described below, a model of elements within a generic vacuum pump is provided. The model is driven by readily available measurements and, by very specific sliding mode analysis of the process dynamics and use of a system of specifically defined driving signals, measures of the deviation in internal parameters of the pump from their nominal values are constructed. 
     A sliding mode observer is described that is used for parameter estimation and fault prediction using non-linear models of the vacuum pump dynamics and appropriate monitoring of the equivalent injection signal. 
     Preferred embodiments of the invention are now described, by way of example only, with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross sectional plan view of a screw pump for use with the present invention; 
         FIG. 2  is a schematic diagram of a double-ended screw pump for use with the present invention; 
         FIG. 3  is a schematic illustration of a side elevation of a pump such as that of  FIG. 1  or  FIG. 2 ; 
         FIG. 4  is a block diagram illustrating the diagnostics subsystem of the present invention; 
         FIG. 5  is a simple block diagram showing the inputs and outputs of a vacuum pump. 
         FIG. 6  shows graphs of measured and estimated body temperature T B1 , model error and corresponding equivalent injection signal in laboratory experiments; 
         FIG. 7  shows measured and estimated data under a fault condition for observers T B1 , T B2  and T o  in laboratory experiments; 
         FIGS. 8 and 9  illustrate, respectively, the equivalent injection signals for the three observers and the component parameter estimate Δ{dot over (m)} c  in the first fault condition; 
         FIG. 10  shows component parameter estimate h c  for observers T B2  and T o  in a second fault condition; and 
         FIG. 11  shows component parameter estimate Δk for observers T B1  and T B2  in a third fault condition. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIG. 1 , a screw pump is illustrated having two rotors  10 , provided within an outer housing  11  that serves as the stator of the pump. The rotors  10  are contra-rotating, intermeshing rollers having their central axis parallel to one another. The rotors are mounted through bearings  15  and are driven by a motor. Ports  12  are optionally provided having nozzles to allow cleaning fluid to be sprayed into the rotors. The pump has an inlet region  13  and an exhaust region  14 . The housing  11  is formed of a two-layer skin, having an inner layer  18  and an outer layer  19 , between which lies a cavity  17  extending over the entire length of the pump.  FIG. 2  shows a double-ended version of a pump, also showing a driving motor  16 . 
     In operation, the motor  16  drives the rotor  10 A (shown lowermost in the diagrams), which in turn drives the contra-rotating rotor. Fluid (such as chemical vapor deposition (CVD) solvent for the semiconductor industry) is pumped from the inlet  13  to the exhaust  14  by the action of screw threads on the rotors. The temperature of the pump is kept under control by pumping of coolant through the cavity  17  to conduct heat away from the pump. 
     Referring to  FIG. 3 , a set of temperature sensors  22 ,  23 ,  24  and  25  are shown at different stages along a pump  21 . These are connected to a temperature monitor  20 . The temperature sensors  22  to  25  monitor the temperature within the cavity  27  at different stages in the pump  21 . A further temperature sensor  26  monitors temperature in the bearings  15  and a temperature sensor  27  monitors coolant outlet temperature. 
     The pump described is a screw pump enclosing two threaded rotors, but alternatively it may be a Northy (“claw”) pump or a Roots pump. 
     The temperature sensors  22  to  27  may be simple thermocouple or thermistor sensors, and for reasons that will be explained, they need not be highly accurate and are therefore relatively inexpensive. 
     Referring now to  FIG. 4 , the temperature sensors  30  are shown as providing measurable vacuum pump data into a sliding mode diagnostics subsystem. The diagnostics subsystem comprises a nominal process model  50  that models the operation of the pump, the model having an output  52  that provides estimates of the measured pump data in accordance with the model. A comparator  54  compares these estimates  52  with the measurable vacuum pump data  30 . The output from the comparator  54  is fed into the model  50  and also into a discontinuous injection module  56  that injects a discontinuous signal into the model  50 . This injection signal causes the model  52  to operate in sliding mode, as will be described below. A signal conditioning module  58  monitors the same discontinuous injection signal from discontinuous injection module  56  (e.g. integrates it over time) and provides an output to estimator  60  that estimates a deviation from a nominal level and generates fault signals or alarms. 
     It is not necessarily contemplated that the fault signal might automatically control the pump or other machine, but this is an option. As an example, a fault indicative of a catastrophic condition or a condition that may be dangerous to the pump or the environment can be used to control the pump, e.g. slow it down or stop it, or to control ancillary equipment connected to the pump, e.g. close or open a valve. 
     The operation of the normal process model  50  and the discontinuous injection module  56  is now described mathematically. 
     If p meas  is a readily measurable process parameter such as pump temperature and p is an estimate of that parameter generated by the nominal process model  50  and if x nominal (t) denotes those parameters which are constant under normal operation but are expected to deviate under faulty operating conditions, c denotes pump parameters that can be assumed to be constant and v is the applied discontinuous injection signal, then: 
     
       
         
           
             
               
                 ⅆ 
                 p 
               
               
                 ⅆ 
                 t 
               
             
             = 
             
               F 
               ⁡ 
               
                 ( 
                 
                   p 
                   , 
                   
                     
                       x 
                       nominal 
                     
                     ⁡ 
                     
                       ( 
                       t 
                       ) 
                     
                   
                   , 
                   c 
                   , 
                   v 
                 
                 ) 
               
             
           
         
       
       
         
           
             v 
             = 
             
               
                 p 
                 - 
                 
                   p 
                   meas 
                 
               
               
                  
                 
                   p 
                   - 
                   
                     p 
                     meas 
                   
                 
                  
               
             
           
         
       
     
     It can now be seen that where x nominal (t) deviates due to a fault, the discontinuous injection signal v will change in order to maintain the estimate p in the nominal process model. This change in v can be measured by signal conditioning module  58  and the resultant estimate of deviation from nominal in the unmeasureable process parameters is output as a possible fault, or may be programmed to cause the generation of an alarm signal. 
     A preferred embodiment of the invention is now described in greater detail with reference to  FIG. 5 , which represents the inputs and outputs of the vacuum pump. 
     Three mathematical models that describe the water-cooling system are derived from physical laws and verified through identification techniques. The system can be represented by means of a block diagram (see  FIG. 5 ). The primary source of heat to the pump is the electrical power supply. Additionally, heat is exchanged between the pump and the atmosphere, the cooling water and pumped gas. 
     A heat transfer model previously developed for a diesel engine by Bhatti et al. described in  Engine coolant system fault diagnostics with sliding mode observers and fuzzy analyser , IASTED International Conference on Modelling, Identification and Control, Innsbruck, Austria, 1999, is modified here. The rate of change of pump body temperature is given by: 
                   (     mc   p     )     B     ⁢       ⅆ     T   B         ⅆ   t         ≈       Q   P     -     Q     C   ⁢           ⁢   W       -     Q   CONV     -     Q   RAD             
where Q denotes an instantaneous heat transfer rate. The instantaneous heat transfer rate of power Q P =kI is assumed to be a function of the inverter current I, where k is a constant. The cooling water heat transfer
   Q   CW   ={dot over (m)}   c   c   pcw ( T   o   −T   i ) 
the surface heat loss to ambient through convection
   Q   CONV =( hA ) B ( T   B   −T   atm ) 
and the surface heat loss to ambient through radiation.
   Q   RAD   =εσA   B ( T   B   4   −T   atm   4 ) 
Moreover, m B  is the mass of the pump body and c pB  is the specific heat capacity of the pump body. T B , T i , T o  and T atm  are the pump body, inlet, outlet and atmospheric temperatures respectively. Also, A B  represents the surface area of the pump body, h B  the heat transfer coefficient of the pump body, {dot over (m)} c  the mass flow rate of coolant through pump, c pcw  the specific heat capacity of the coolant, ε the surface emissivity and σ the Steffen-Boltzmann constant.
 
     Substituting for Q will result in the following equation: 
                   (     mc   p     )     B     ⁢       ⅆ     T   B         ⅆ   t         =       k   ⁢           ⁢   I     -         m   .     c     ⁢       c   pcw     ⁡     (       T   o     -     T   i       )         -         (     h   ⁢           ⁢   A     )     B     ⁢     (       T     B   ⁢           ⁢   1       -     T   atm       )       -     ɛσ   ⁢           ⁢       A   B     ⁡     (       T   B   4     -     T   atm   4       )                 
By rearranging the relationship and assuming the radiation losses to be small:
 
                 ⅆ     T     B   ⁢           ⁢   1           ⅆ   t       =         k   ⁢           ⁢   I         (     mc   p     )     B       -             m   .     c     ⁢     c   pcw           (     mc   p     )     B       ⁢     (       T   o     -     T   i       )       -           (     h   ⁢           ⁢   A     )     B         (     mc   p     )     B       ⁢     (       T     B   ⁢           ⁢   1       -     T   atm       )               
Re-labelling the coefficients for ease of exposition yields:
   {dot over (T)}   B1   =a   1   kI−a   2   {dot over (m)}   c ( T   o   −T   i )− a   3 ( T   B1   −T   atm )   (1) 
where a 1 ,a 2  and a 3  are given by a 1 =1/(mc p ) B , a 2 =c pcw /(mc p ) B  and a 3 =(hA) B /(mc p ) B .
 
     In equation (1), the rate of change of pump body temperature (T B1 ) is parameterized in terms of the mass flow rate, but it can be also parameterized in terms of the heat transfer coefficient between the pump and the coolant h c  (T B2 ). This will result in: 
                 ⅆ     T     B   ⁢           ⁢   2           ⅆ   t       =         k   ⁢           ⁢   I         (     mc   p     )     B       -           h   c     ⁢           ⁢     A   c           (     mc   p     )     B       ⁢     (       T     B   ⁢           ⁢   2       -     T   o       )       -           (     h   ⁢           ⁢   A     )     B         (     mc   p     )     B       ⁢     (       T     B   ⁢           ⁢   2       -     T   atm       )               
where A C  is the surface area of the surrounding pipe-work. Hence,
   {dot over (T)}   B2   =a   1   kI−a   4   h   c ( T   B2   −T   o )− a   3 ( T   B2   −T   atm )  (2) 
where a 4 =A C /(mc p ) B .
 
Finally, the rate of change of the coolant temperature is given by:
 
                   (     m   ⁢           ⁢     c   p       )     cw     ⁢       ⅆ     T   o         ⅆ   t         =       Q   C     -     Q     C   ⁢           ⁢   W       -     Q     C   ⁢           ⁢   W                   where                 Q   C     =       h   c     ⁢       A   c     ⁡     (       T   B     -     T   o       )           ⁢                 
is the pump body to coolant heat transfer and
   Q   CW   ={dot over (m)}   c   c   pcw ( T   o   −T   i ) 
the cooling water heat transfer. In addition, m cw  is the mass of the coolant contained in the pump. Substituting the instantaneous heat transfer rate and rearranging:
 
                 ⅆ     T   o         ⅆ   t       =             h   c     ⁢           ⁢     A   c           (     mc   p     )     cw       ⁢     (       T   B     -     T   o       )       -             m   .     c     ⁢     c   pcw           (     mc   p     )     cw       ⁢     (       T   o     -     T   i       )               
Therefore, renaming the coefficients gives:
   {dot over (T)}   o   =b   1   h   c ( T   B   −T   o )− b   2   {dot over (m)}   c ( T   o   −T   i )  (3) 
where b 1  and b 2  are given by b 1 =A c /(mc p ) cw  and b 2 =1/m cw .
 
     Equations (1)-(3) represent the dynamics of the cooling system. It is useful to consider the possible variation in the system parameters that may be used to indicate likely malfunction of the system: a variation in the coolant mass flow rate {dot over (m)} c , a change in the heat transfer coefficient h c  between the pump and coolant and a change in the heat transfer k between the pump and the temperature sensor. Let
 
 {dot over (m)}   c   ={dot over ({tilde over (m)}   c   +Δ{dot over (m)}   c   , h   c   ={tilde over (h)}   c   +Δh   c  and  k={tilde over (k)}+Δk  
 
where Δ{dot over (m)} c ,Δh c ,Δk represent the deviations and {dot over ({tilde over (m)} c ,{tilde over (h)} c ,{tilde over (k)} the nominal parameters. Substituting the above in equations (1), (2) and (3) gives:
 
 {dot over (T)}   B1   =a   1   I ( {tilde over (k)}+Δk )− a   2   T   o ( {dot over ({tilde over (m)}   c   +Δ{dot over (m)}   c )+ a   2   T   i ( {dot over ({tilde over (m)}   c   +Δ{dot over (m)}   c )− a   3   T   B1   +a   3   T   atm    (4)
 
 {dot over (T)}   B2   =a   1   I ( {tilde over (k)}+Δk )− a   4   T   B2 ( {tilde over (h)}   c   +Δh   c )+ a   4   T   o ( {tilde over (h)}   c   +Δh   c )− a   3   T   B2   +a   3   T   atm    (5)
 
 {dot over (T)}   o   =b   1   T   B ( {tilde over (h)}   c   +Δh   c )− b   1   T   o ( {tilde over (h)}   c   +Δh   c )− b   2   T   o ( {dot over ({tilde over (m)}   c   +Δ{dot over (m)}{dot over ( )}   c )+ b   2   T   i ( {dot over ({tilde over (m)}   c   +Δ{dot over (m)}   c )   (6)
 
It can be observed that by setting the deviations Δ{dot over (m)} c ,Δh c ,Δk to zero in the above equations a nominal cooling system dynamics can be obtained.
 
     The sliding mode observer considered for the purposes of the present invention is used for parameter estimation and hence fault prediction of the cooling water system. Therefore, the sliding surface has been chosen to be the error between the observer (model) output and the plant (pump) output. The output of the comparator  54  (the error signal) is input to the discontinuous injection module  56 , which generates an injection signal (which may comprise multiple components, described in greater detail below) as a function of the sign of the error, to adjust the state of the model to cause the error to tend to zero. It will be illustrated that the sliding motion will be attained even in the presence of a fault and the resulting equivalent injection signal will be used to reconstruct the model parameters. 
     The proposed observer has been modified from Goh et al. (2002),  Fault diagnostics using sliding mode techniques , Control Engineering Practice, Vol. 10, 207-217 and has the following structure:
 
 {dot over ({circumflex over (T)}   B1   =−a   3   {circumflex over (T)}   B1   +a   1   {tilde over (k)}I−a   2   {dot over ({tilde over (m)}   c   T   o   +a   2   {dot over ({tilde over (m)}   c   T   i   +a   3   T   atm +υ B1   (7)
 
 {dot over ({circumflex over (T)}   B2 =−( a   4   {tilde over (h)}   c   +a   3 ) {circumflex over (T)}   B2   +a   1   {tilde over (k)}I+a   4   {tilde over (h)}   c   T   o   +a   3   T   atm +υ B2   (8)
 
 {dot over ({circumflex over (T)}   o =−( b   1   {tilde over (h)}   c   +b   2   {dot over ({tilde over (m)}   c ) {circumflex over (T)}   o   +b   1   {tilde over (h)}   c   T   B   +b   2   {dot over ({tilde over (m)}   c   T   i +υ o    (9)
 
     where υ i =K i (ε i /∥ε i ∥+δ), i= B1,B2,o  and K i  are the gains of the discontinuous signals υ i . Moreover, the ε i  is the observer error defined as the difference between the estimated and measured temperatures (i.e. ε B1 =T B1 −{circumflex over (T)} B1 , ε B2 =T B2 −{circumflex over (T)} B2  and ε o =T o −{circumflex over (T)} o ). The selection of K i  must be such that the reachability problem is satisfied and the sliding motion is sustained at all times. Finally, δ is the usual small positive constant used to reduce ‘chattering’, see Edwards et al. (1998),  Sliding Mode Control: Theory and Application , Taylor and Francis, UK. 
     The following equations yield the observer error dynamics:
 
{dot over (ε)} B1   =−a   3 ε B1   +a   1   ΔkI−a   2   Δ{dot over (m)}   c ( T   o   −T   i )−υ B1   (10)
 
{dot over (ε)} B2 =−( a   4   {tilde over (h)}   c   +a   3 )ε B2   +a   1   ΔkI−a   4   Δh   c   T   B2   +a   4   Δh   c   T   o −υ B2   (11)
 
{dot over (ε)} o =−( b   1   {tilde over (h)}   c   +b   2   {dot over ({tilde over (m)}   c )ε o −( b   1   Δh   c   +b   2   Δ{dot over (m)}   c ) T   o   +b   1   Δh   c   T   B   +b   2   Δ{dot over (m)}   c   T   i −υ o    (12)
 
     Assuming the K i  are chosen sufficiently large, a sliding mode will be attained and maintained. The observer errors and their derivatives will converge to zero due to the choice of sliding surface. Thus, the sliding mode equations (10), (11) and (12) become:
 
0 =a   1   ΔkI−a   2   Δ{dot over (m)}   c ( T   o   −T   i )−υ B1    (13)
 
0 =a   1   ΔkI−a   4   Δh   c   T   B2   +a   4   Δh   c   T   o −υ B2    (14)
 
0=−( b   1   Δh   c   +b   2   Δ{dot over (m)}   c ) T   o   +b   1   Δh   c   T   B   +b   2   Δ{dot over (m)}   c   T   i −υ o    (15)
 
     Equations (13), (14) and (15) demonstrate that the observer provides a means of detecting changes in system parameters. It can also be observed that the system parameters are interdependent and more than one injection signal must be utilised to perform fault diagnosis. The idea is illustrated in Table 1 below: 
     
       
         
               
             
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Fault conditions 
               
             
          
           
               
                   
                   
                 Average Value of Injection 
               
               
                   
                 Fault 
                 Signal 
               
             
          
           
               
                   
                 Condition 
                 υ B1   
                 υ B2   
                 υ o   
               
               
                   
                   
               
               
                   
                 Δ{dot over (m)} c   
                 Non- 
                 0 
                 Non- 
               
               
                   
                   
                 zero 
                   
                 zero 
               
               
                   
                 Δh c   
                 0 
                 Non- 
                 Non- 
               
               
                   
                   
                   
                 zero 
                 zero 
               
               
                   
                 Δk 
                 Non- 
                 Non- 
                 0 
               
               
                   
                   
                 zero 
                 zero 
               
               
                   
                 Normal 
                 0 
                 0 
                 0 
               
               
                   
                 Condition 
               
               
                   
                   
               
             
          
         
       
     
     υ B1 , υ B2  and υ o  are different injection signals injected to keep the model in sliding mode. If the first row of results is obtained (i.e. the first and third signals show significant value deviations from nominal), this is indicative of a mass flow rate problem, for example a valve problem or a blockage. If the second row of results is obtained (the first and second signals exceed their thresholds) this is indicative of a pump/coolant heat transfer problem—i.e. something getting too hot (or conceivably something getting unexpectedly cool). If the third row of results is obtained, this is indicative of abnormal pump/sensor heat transfer. 
     Thus, a truth table can be constructed for these or other parameters to diagnose more than one fault condition from several injection signals, and logic circuitry or processing can be used to diagnose the conditions. 
     A dry vacuum pump was tested under laboratory conditions. Temperature sensors were fitted on the vacuum pump in order to deliver status information. The motor current was also captured from the system&#39;s inverter via a serial link. 
     dSPACE (Digital Signal Processing and Control Engineering) a suitable hardware interface. It provides all the tools needed for real-time data acquisition and direct data exchange with Matlab/Simulink. Finally, a digital low pass filter was employed to remove the high frequency components. 
     In order to replicate the changes in system parameters that may occur prior to pump failure, three different experimental scenarios were considered. A low flow or total coolant failure will result in high temperatures in the motor, stator and the bearings. These high temperatures will affect the vacuum pump and can result in total failure. In order to simulate this type of fault the control valve was used to restrict the water flow. Secondly, a reduction in the rate of heat transfer from pump to coolant which can be caused by deposits on the coolant flow pipe-work is investigated. This type of fault was simulated by inserting an insulating material between the vacuum pump and the pipe-work. The last type of fault examined was a change in the heat transfer between the pump and the temperature sensor. For example additional heat generated by bearing friction. The fault was simulated by fitting a heater externally on the bearings. 
     Some results are now described with reference to  FIGS. 6 to 11 . These results show the behavior of observer T B1  under normal operating conditions. 
     In  FIG. 6 , the first graph represents a plot of the measured and the estimated data from the sliding mode observer. It can be noticed from the second graph that the observer tracks the temperature data very well and that the corresponding error between them is of the order of 0-0.002° C. The third graph represents the equivalent injection signal υ B1 . Note that it is not affected and remains close to zero under normal operating conditions. 
     Referring to  FIG. 7 , this figure shows measured and estimated data under a fault condition for observers T B1 , T B2  and T o  in laboratory experiments. It can be seen that at approximately 3200 seconds a fault in the coolant mass flow rate {dot over (m)} c  is introduced by restricting the water flow. Nevertheless, all the three observers attain a sliding motion even in the presence of the fault. 
       FIG. 8  shows the injection signals υ B1 , υ B2  and υ o  for coolant flow failure, while  FIG. 9  shows component parameter estimate Δ{dot over (m)} c  for observers T B1  and T o . The proposed diagnostic technique indicates that the parameters are interdependent so that the diagnostic system must detect non-zero values in more than one injection signal to infer a fault. As predicted, signals υ B1  and υ o  are affected, whereas υ B2  is largely unaffected. Also, good correlation between the estimates of Δ{dot over (m)} c  is observed. 
       FIGS. 10 and 11  show the non-zero parameter estimates for the remaining two fault situations. In  FIG. 10 , a change in the heat transfer coefficient h c  between the pump and coolant is introduced at approximately 2800 seconds. It can be seen that both observers reconstruct this change successfully. In  FIG. 11 , a change in the heat transfer k between the pump and the temperature sensor is introduced by the addition of approximately 120 W at 1700 and 3500 seconds respectively. 
       FIGS. 9 and 10  show the non-zero parameter estimates for the remaining two fault situations.  FIG. 9  shows the injection signals υ B1 , υ B2  and υ o  for coolant flow failure, while  FIG. 10  shows component parameter estimate Δ{dot over (m)} c  for observers T B1  and T o . A change in the heat transfer coefficient h c  between the pump and coolant is introduced at approximately 2800 seconds. It can be seen that both observers reconstruct this change successfully. Moreover, a change in the heat transfer k between the pump and the temperature sensor is introduced by the addition of approximately 120 W at 1700 and 3500 seconds respectively. 
     It has been shown that, when using a sliding mode approach, parameter estimation and hence fault prediction can be achieved by examining the associated equivalent injection signal. The method adopted here was successfully employed in a dry vacuum pump. The results show good correlation between the system parameter estimates obtained from the different observers. Early detection of faults is possible. Further, the suggested fault diagnostic technique provides a cost-effective approach which requires only minimal transducer information. 
     The technique described and claimed can be used to augment existing condition monitoring tools that are implemented on vacuum pumps. Measurements from inexpensive and readily available existing transducers can be taken and used to construct estimates of internal parameters of the machine. These internal parameters are impractical to measure using existing transducers and knowledge of the variation in such parameters is critical to predictive diagnostics relating to the health of the machine. By detailed modelling of the vacuum pump and the appropriate equivalent injection analysis, very accurate estimates of these internal parameters can be obtained.