Research on the new mode of intelligent maintenance and health management of coal mine equipment

Based on the analysis of the current challenges and deficiencies in the maintenance and management of coal mine equipment, an intelligent maintenance and health management system framework for coal mine equipment is designed for the big data characteristics of the life cycle of coal mine equipment. Taking the big data processing and analysis of coal mine equipment as the main line, it proposes and elaborates the key technologies of the intelligent maintenance and health management of coal mine equipment driven by big data, including the unified description and analysis of multi-source heterogeneous big data, and intelligent fault diagnosis of coal mine equipment. Technology, health evaluation and prediction technology, intelligent maintenance decision-making technology, etc. Through the implementation of the above-mentioned system architecture and key technologies, data-driven life-cycle intelligent decision-making is realized, which promotes the continuous optimization and improvement of equipment process management and reduces business costs. The proposed system architecture provides a reference model for subsequent development.

Lifetime Benefit Analysis of Intelligent Maintenance: Simulation Modeling Approach and Industrial Case Study

The introduction of Industry 4.0 is expected to revolutionize current maintenance practices by reaching new levels of predictive (detection, diagnosis, and prognosis processes) and prescriptive maintenance analytics. In general, the new maintenance paradigms (predictive and prescriptive) are often difficult to justify because of their multiple inherent trade-offs and hidden systems causalities. The prediction models, in the literature, can be considered as a “black box” that is missing the links between input data, analysis, and final predictions, which makes the industrial adaptability to such models almost impossible. It is also missing enable modeling deterioration based on loading, or considering technical specifications related to detection, diagnosis, and prognosis, which are all decisive for intelligent maintenance purposes. The purpose and scientific contribution of this paper is to present a novel simulation model that enables estimating the lifetime benefits of an industrial asset when an intelligent maintenance management system is utilized as mixed maintenance strategies and the predictive maintenance (PdM) is leveraged into opportunistic intervals. The multi-method simulation modeling approach combining agent-based modeling with system dynamics is applied with a purposefully selected case study to conceptualize and validate the simulation model. Three maintenance strategies (preventive, corrective, and intelligent) and five different scenarios (case study data, manipulated case study data, offshore and onshore reliability data handbook (OREDA) database, physics-based data, and hybrid) are modeled and simulated for a time period of 20 years (175,200 h). Intelligent maintenance is defined as PdM leveraged in opportunistic maintenance intervals. The results clearly demonstrate the possible lifetime benefits of implementing an intelligent maintenance system into the case study as it enhanced the operational availability by 0.268% and reduced corrective maintenance workload by 459 h or 11%. The multi-method simulation model leverages and shows the effect of the physics-based data (deterioration curves), loading profiles, and detection and prediction levels. It is concluded that implementing intelligent maintenance without an effective predictive horizon of the associated PdM and effective frequency of opportunistic maintenance intervals, does not guarantee the gain of its lifetime benefits. Moreover, the case study maintenance data shall be collected in a complete (no missing data) and more accurate manner (use hours instead of date only) and used to continuously upgrade the failure rates and maintenance times.

An Intelligent Fleet Condition-Based Maintenance Decision Making Method Based on Multi-Agent

According to the demand for condition-based maintenance online decision making among a mission oriented fleet, an intelligent maintenance decision making method based on Multi-agent and heuristic rules is proposed. The process of condition-based maintenance within an aircraft fleet (each containing one or more Line Replaceable Modules) based on multiple maintenance thresholds is analyzed. Then the process is abstracted into a Multi-Agent Model, a 2-layer model structure containing host negotiation and independent negotiation is established, and the heuristic rules applied to global and local maintenance decision making is proposed. Based on Contract Net Protocol and the heuristic rules, the maintenance decision making algorithm is put forward. Finally, a fleet consisting of 10 aircrafts on a 3-wave continuous mission is illustrated to verify this method. Simulation results indicate that this method can improve the availability of the fleet, meet mission demands, rationalize the utilization of support resources and provide support for online maintenance decision making among a mission oriented fleet.

Aircraft Engine Run-to-Failure Dataset under Real Flight Conditions for Prognostics and Diagnostics

A key enabler of intelligent maintenance systems is the ability to predict the remaining useful lifetime (RUL) of its components, i.e., prognostics. The development of data-driven prognostics models requires datasets with run-to-failure trajectories. However, large representative run-to-failure datasets are often unavailable in real applications because failures are rare in many safety-critical systems. To foster the development of prognostics methods, we develop a new realistic dataset of run-to-failure trajectories for a fleet of aircraft engines under real flight conditions. The dataset was generated with the Commercial Modular Aero-Propulsion System Simulation (CMAPSS) model developed at NASA. The damage propagation modelling used in this dataset builds on the modelling strategy from previous work and incorporates two new levels of fidelity. First, it considers real flight conditions as recorded on board of a commercial jet. Second, it extends the degradation modelling by relating the degradation process to its operation history. This dataset also provides the health, respectively, fault class. Therefore, besides its applicability to prognostics problems, the dataset can be used for fault diagnostics.