Exploring Prognostic and Diagnostic Techniques for Jet Engine Health Monitoring: A Review of Degradation Mechanisms and Advanced Prediction Strategies
Abstract
:1. Introduction
2. Degradation Mechanisms of an Aircraft Engine
2.1. Fouling
2.2. Erosion
2.3. Corrosion
2.4. Abrasion
2.5. Thermal Distortion
2.6. Foreign Object Damage and Domestic Object Damage
2.7. Increased Blade Tip Clearance
2.8. Summary of Degrading Phenomena
3. Data Acquisition and Processing
3.1. Sensor Measurements
3.2. Data Reduction Techniques
3.2.1. PCA
- Input: ; Output: ;
- Build the covariance matrix ;
- Obtain Eigen values and Eigen vectors by applying Eigen decomposition to ;
- Sort Eigen values from the higher to the lower;
- Build the dxk transformation matrix W with k top Eigen vectors;
- Uses W to transform X to obtaining the new subspace Y = XW.
3.2.2. KPCA
- Input: ; Output: ;
- Produce linear data with kernel mapping function to ;
- Uses the common PCA to , obtaining reduced space Y.
3.2.3. LDA
- Input: ; Output: ;
- Obtain two scatter matrices of : in-between-class and within-class;
- Calculate the eigen values and eigen vectors of the scatter matrices;
- Rank eigen vectors in descending order, based on eigen values;
- Build the transformation dxk matrix W with k top eigen vectors;
- Uses W to transform X to obtaining the new subspace Y = XW.
3.2.4. MDS
- Input: ; Output: ;
- Obtain the dissimilarity matrix ;
- Compute by utilizing the centering matrix ;
- Uses eigen decomposition with to have top Eigen values and corresponding vectors;
- Provide using diagonal matrix and top Eigen vectors.
3.2.5. SVD
- Input: ; Output: ;
- Decompose into matrices , and ;
- Obtain by selecting top singular values from S.
3.2.6. LLE
- Input: ; Output: ;
- Find the c-nearest neighbors for each data point of ;
- Calculate local weights with which data are best reconstructed () from their neighbors;
- Use the weights from the previous step to map to on -dimensions by minimizing the cost.
3.2.7. ISOMAP
- Input: ; Output: ;
- Obtain the neighborhood graph of ;
- Compute the matrix of the geodesic distances;
- Use MDS method with to obtain the new space Y.
3.2.8. LE
- Input: ; Output: ;
- Construct the neighborhood graph of using adjacency matrix ;
- Compute the weights of the edges of ;
- Optimize the cost function to obtain the new space Y.
3.2.9. ICA
- Input: ; Output: ;
- Performs a decomposition of to and ;
- Select top independent components;
- Obtain exploiting the components.
3.2.10. t-SNE
- Input: ; Output: ;
- Compute the conditional probabilities and ;
- Minimize the difference between and to perform a mapping process of to .
3.2.11. Summary of Data Reduction Methods
4. Diagnostic and Prognostic Techniques
4.1. Model-Based Methods
4.1.1. Gas Path Analysis (GPA)
4.1.2. Kalman Filters (KFs)
4.1.3. Genetic Algorithms (GAs)
4.2. Data-Driven Methods
4.2.1. Artificial Neural Networks (ANNs)
4.2.2. Bayesian Belief Networks (BBNs)
4.2.3. Expert Systems (ESs)
4.2.4. Fuzzy Logic (FL)
4.2.5. Support Vector Machine (SVM)
4.3. Final Summary
5. Conclusions
- i.
- Lack of standardization: The field currently lacks standardized techniques and metrics for monitoring degradation, which can lead to inconsistencies across studies. Developing standardized techniques could help improve the reliability and consistency of results.
- ii.
- Limited real-world testing: Most studies on degradation health monitoring techniques have been conducted in laboratory or simulated environments, which may not accurately represent real-world conditions. Further testing in real-world environments could provide more relevant and realistic data.
- iii.
- Lack of comparative studies: While many studies have evaluated the performance of individual monitoring techniques, there is a lack of comparative studies that assess the strengths and weaknesses of different techniques for monitoring the same type of degradation.
- iv.
- Insufficient consideration of uncertainty: Many monitoring techniques provide point estimates of degradation levels without accounting for the uncertainty associated with these estimates. Considering uncertainty could improve the reliability of degradation predictions.
- v.
- Limited consideration of multiple degradations: Many studies focus on monitoring a single type of degradation, but real-world systems often experience multiple degradations simultaneously. Exploring how to monitor multiple degradations could provide a more comprehensive understanding of system health.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Strategy | Principle | Data Required | Data Analysis | Maintenance Decision | Related Problems | Refs. |
---|---|---|---|---|---|---|
CM | Reactive-based; Unscheduled; Fail and fix approach. | No data measurements are required. Corrective maintenance is based on visual inspections. | No data to analyze. | Maintenance is performed only after a detected failure by a visual inspection. | Faults cannot be predicted and are not avoided by scheduled maintenance; Higher maintenance costs; Lower reliability compared to other maintenance strategies. | [4,12,13] |
PM | Time-based; Scheduled. Maintenance interval depends on the probability of failure occurring; Preventive approach. | Historical data on components failure or test data. | A reliability theory based on bathtub curve assumptions. | Maintenance is performed after predetermined time intervals, obtained from statistical analysis of available historical data about failure of components or test data. | The maintenance plan is based on statistical assumptions. A component could be overhauled even if in good condition or could be subject to a fault before being overhauled; Higher maintenance costs and lower reliability compared to the predictive strategy. | [5,6,12,13] |
CBM | Condition-based; Just-in-time. Maintenance interventions request only when necessary; Preventive and predictive approach. | Information about actual values of some parameters used as health indicators of the components (temperatures, pressures, etc.). | Monitoring the component state of health. | Maintenance is performed when monitored parameters indicate an impending failure in one or more components. | More complex approach; Require more efforts and time for strategy development. | [5,7,8,9,10,12,13] |
Performance Parameter | Metric Unit | Engine Type |
---|---|---|
Measurable * | ||
Exhaust gas temperature (EGT) | °C | Aero jet engines |
Fuel flow | kg/s | All types |
High-pressure spool speed | RPM | Aero jet engines |
Low-pressure spool speed | RPM | Two-spool GT |
Intermediate-pressure spool speed | RPM | Three-spool GT |
Compressor outlet pressure | kPa | Aero jet engines |
Compressor outlet temperature | °C | Aero jet engines |
Turbine inlet temperature | °C | Aero jet engines |
Torque | Nm | Turboshaft/Turboprop |
Component vibration | m/s2 | All types |
Estimated * | ||
Power | kW | Piston engine/APU |
Thrust | kN | Aero jet engines |
Specific fuel consumption | Kg/kJ | Piston engine |
Thrust specific fuel consumption | g/(kN·s) | Aero jet engine |
Air flow | kg/s | All types |
Exhaust gas flow | kg/s | Aero jet engines |
Exhaust gas velocity | m/s | Aero jet engines |
Heat rate | kJ/kWh | All types |
Thermal efficiency | % | All types |
Phenomenon | Mechanism | Exposed Parts | Effects on Parts | Effects on Performance Parameters of Parts | Effects on Engine Performance | Refs. |
---|---|---|---|---|---|---|
Fouling | Contaminant particles adhesion on surfaces and blades. | Compressors and turbines. Mainly the compressors. | Change in aerodynamic shape and inlet angle of airfoils; increase in surface roughness and decrease in airfoil throat opening. | Fouled compressor: decrease in ηc, fc and βc; Fouled turbine: decrease in ηt and ft. | Drop in output power and thermal efficiency and increase in heat rate. | [39,40,41,42,43,44,45,46,47,48,49,50,51] |
Erosion | Loss in material from gas path due to impact with harder and bigger contaminant particles. | Compressors and turbines. Mainly the turbines. | Change in the aerodynamic shape of blades. Increase in roughness and decrease in cross-sectional area. | Eroded compressor: decrease in ηc, fc and βc; Eroded turbine: decrease in ηt and increase in ft. | Drop in output power and increase in heat rate. | [39,42,54,55,56,57,58,59,60,61,62,63,64,65,66,67,68,69] |
Corrosion | Loss of material in gas path due to chemical reactions between gas-path materials and contaminants. | Compressors and turbines. Cold corrosion is relevant in compressors. Hot corrosion is relevant in turbines. | Change in the aerodynamic shape of blades. Increase in roughness. | Corroded compressor: decrease in ηc and fc; Corroded turbine: decrease in ηt and increase in ft. | Drop in output power and increase in heat rate. | [70,71,72,73,74,75,76,77,78] |
Abrasion | Loss in material due to a component rubbing on another one. | Compressors and turbines. | Increase in seal and tip gaps. | Abraded compressor: decrease in ηc; Abraded turbine: decrease in ηt. | Drop in output power. | [78,79,80,81,82] |
Thermal distortion | Damages in parts located at burner exit due to a change in radial and circumferential temperature patterns. | Burner exit/turbine inlet. | Generation of cracks, bends, warpings, burns in turbine nozzle guide vanes and change in nozzle guide vanes areas. | Decrease in ηt. | Drop in output power. | [26,78] |
FOD/DOD | Impact with an ingested object or with detached ones from engine components, respectively. | Compressors and turbines. | Bends and breaks in blades. | Affected compressor: decrease in ηc and increase or decrease in fc; Affected turbine: decrease in ηt and increase or decrease in ft. | Drop in output power, increase in heat rate. | [39,42,78,83] |
Increase in blade tip clearance | Increase in clearance between moving blades and stationary blades with casing and rotating hub, respectively. | Compressors and turbines. | Tip breaks and consequent increase in clearance. | Affected compressor: decrease in ηc and fc; Affected turbine: decrease in ηt and ft. | Drop in output power and increase in heat rate. | [33,84,85,86,87,88,89,90,91,92,93,94,95] |
Notation | Definition |
---|---|
PC | Principal component |
X | Input dataset in high dimension |
Y | Output dataset in low dimension |
d | Original high dimension |
k | New low dimension |
ath input data in d dimension | |
bth input data in d dimension | |
ath output data in k dimension | |
bth output data in k dimension | |
K | Kernel function |
c | Nearest neighbors for a data point |
n | Number of data points |
i | Number of iterations |
Kernel | Description |
---|---|
Linear: | Generally used when data are linearly separable. |
Polynomial: | Shows the similarity among data in a feature space over the polynomials of actual variables. |
Gaussian: | Used when data are non-linearly separable. |
Sigmoid: | Mostly used in neural networks. |
Method | Supervision | Coupled with | Advantages | Disadvantages | In EHM |
---|---|---|---|---|---|
PCA | Unsupervised | ANN * [113,114]. | Eliminates the correlation between the features. Improves data visualization. | Not adaptive to nonlinear cases. Do not work in cases in which mean and covariance do not completely define the dataset. | [113,114] |
LDA | Supervised | TET *. | Data are classified into groups. | Suffers from a class singularity issue. | [118] |
MDS | Unsupervised | FCM *. | Preserves the distances in cases in which it is difficult to represent a low number of dimensions [128]. | Needs a lot of computation and memory. | [119] |
KPCA | Unsupervised | ANN [115,117]. | More suitable in nonlinear cases. | Long training time. | [115,117] |
SVD | Unsupervised | ANN. | Works efficiently with sparse matrices. | Not adaptive to nonlinear cases. | [120] |
LLE | Unsupervised | KSR *. | Fast and capable of preserving local geometry. | Requires more memory and less efficient with noised data. | [121] |
ISOMAP | Unsupervised | Not specified classifier. | Relationship between data points is preserved. | Suffers from topological instability. | [122] |
LE | Unsupervised | SVM * for diagnostics and PHM * for prognostics. | Gives a unique solution. | May produce disconnected neighborhood graph. | [123] |
ICA | Supervised | Used as denoiser in electrostatic monitoring [124]; SVM [125]. | Is able to filter noise from the signal. | Long training time. | [124,125] |
t-SNE | Unsupervised | No diagnostic or prognostic algorithms. Based on spatial structural characteristics of QAR * data [126]; ANN [127]. | Works efficiently with nonlinear data. | Provides only 2 or 3 features. Computationally complex. | [126,127] |
Method | Type | Purposes | Machine | Data Type | Noise | Used Software | Refs. |
---|---|---|---|---|---|---|---|
KF | MB * | Diagnostics | Military twin-spool turbofan engine | Model data | Yes | - | [149] |
KF | MB * | Prognostics | Aircraft fuel feed system | Model data | Yes | - | [159] |
GA | MB * | Diagnostics | Aircraft two-shaft turbofan engine | Model data | No | Pythia | [169] |
ANN/SVM | DD * | Performance analysis and diagnostics | Aircraft single-spool turbojet engine (Rolls Royce VIPER 632-43) | Measured and Model data | Yes | ONX and AEDSYS coupled MATLAB routines | [178] |
ANN | DD * | Prognostics | Aircraft turbofan engine | Model data | - | ProDiMES for simulations; MATLAB for ANN implementation | [179] |
BBN | DD * | Diagnostics | Aircraft turbofan engine | Measured and Model data | Yes | - | [183] |
BBN | DD * | Diagnostics | Aircraft turbofan engine (GE CFM56-7) | Model data | - | MATLAB | [184] |
BBN | DD * | Prognostics | Aircraft brake | Measured data | - | - | [185] |
FL | DD * | Diagnostics | Military three-spool turbofan engine | Model data | Yes | Turbomatch for data generation; MATLAB for fuzzy logic implementation | [195] |
FL | DD * | Diagnostics | Aircraft turbofan engine | Model data | Yes | - | [196] |
Method | Pre-Processing | Metrics | Accuracy Based on Metrics on the Third Column | Type of Degradation | Refs. |
---|---|---|---|---|---|
KF | - | Minimum bias which can be isolated | 0.8% | FOD, considering two different baselines, one healthy and one degraded, together with sensors and actuator faults | [149] |
KF | Feature extraction and filtering | MSE | Between 0.000168 and 0.214 | Cavitation erosion in booster pump | [159] |
GA | - | Fitness (consult the paper for the definition) | Between 0.35 and 1 | Power-setting sensor fault (with and without the presence of engine component degradation and other gas path sensor faults) | [169] |
ANN/SVM | - | (a) Performance prediction: RMSE; (b) Diagnostics: prediction efficiency | (a) Between 0.019 and 0.0089; (b) Prediction efficiency between 80% and 100% in diagnostics | Compressor fouling and turbine erosion, one at a time and simultaneously | [178] |
ANN | - | - | - | Fan abrupt fault | [179] |
BBN | Filtering | Number of cases correctly diagnosed | 13 out of 15 with measured data; About 90% during climb and cruise and about 60% during descent with model data | Different fault cases, including fault in FAN, LPC *, HPC *, HPT *, LPT * and nozzle | [183] |
BBN | - | % of correct: (a) Identification; (b) Isolation | (a) Between 19.17% and 100%; (b) Between 7.33% and 86.79% | No degradation type is specified | [184] |
BBN | - | Error between real and predicted brake wear | Between 4.0036 and 0.8012 in absolute value at last prediction | Brake wear | [185] |
FL | - | Average percentage error between predicted and target | 7.5% | IPC * fault | [195] |
FL | - | % of correct fault isolation | Between 89% and 100% | FAN, LPC *, HPC *, HPT * and LPT * fault | [196] |
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De Giorgi, M.G.; Menga, N.; Ficarella, A. Exploring Prognostic and Diagnostic Techniques for Jet Engine Health Monitoring: A Review of Degradation Mechanisms and Advanced Prediction Strategies. Energies 2023, 16, 2711. https://doi.org/10.3390/en16062711
De Giorgi MG, Menga N, Ficarella A. Exploring Prognostic and Diagnostic Techniques for Jet Engine Health Monitoring: A Review of Degradation Mechanisms and Advanced Prediction Strategies. Energies. 2023; 16(6):2711. https://doi.org/10.3390/en16062711
Chicago/Turabian StyleDe Giorgi, Maria Grazia, Nicola Menga, and Antonio Ficarella. 2023. "Exploring Prognostic and Diagnostic Techniques for Jet Engine Health Monitoring: A Review of Degradation Mechanisms and Advanced Prediction Strategies" Energies 16, no. 6: 2711. https://doi.org/10.3390/en16062711
APA StyleDe Giorgi, M. G., Menga, N., & Ficarella, A. (2023). Exploring Prognostic and Diagnostic Techniques for Jet Engine Health Monitoring: A Review of Degradation Mechanisms and Advanced Prediction Strategies. Energies, 16(6), 2711. https://doi.org/10.3390/en16062711